Morningstar TriStar MPPT Series Installation, Operation And Maintenance Manual
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Morningstar TriStar MPPT Series Installation, Operation And Maintenance Manual

Solar charging system controller
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T
S
TM
RI
TAR MPPT
Solar Charging System Controller
Installation, Operation and Maintenance Manu al
For the most recent manual revisions, see the version at:
www.morningstarcorp.com
Solar Battery Charger
With
TM
TrakStar
Maximum Power Point Tracking Technology
www.morningstarcorp.com
MODELS
TS-MPPT-30
TS-MPPT-45
TS-MPPT-60

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Summary of Contents for Morningstar TriStar MPPT Series

  • Page 1 TAR MPPT Solar Charging System Controller Installation, Operation and Maintenance Manu al 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-30 TS-MPPT-45 TS-MPPT-60...
  • Page 2 Dimensions in Inches [Millimeters]...

  • Page 3: Important Safety Instructions

    1.0 Important Safety Instructions SAVE THESE INSTRUCTIONS. This manual contains important safety, installation and operating instructions for the TriStar MPPT 150V solar controller. The following symbols are used throughout this manual to indicate potentially dangerous conditions or mark important safety instructions: WARNING: Indicates a potentially dangerous condition.
  • Page 4 • by the symbol below: Direct Current Symbol The TriStar MPPT 150V controller must be installed by a qualified technician in accordance with the electrical regulations of the country where the product is installed. A means of disconnecting all power supply poles must be provided. These disconnects must be incorporated in the fixed wiring. A permanent, reliable earth ground must be established with connection to the wiring compartment ground terminal.
  • Page 5 • Servicing of batteries should be performed, or supervised, by personnel knowledgeable about batteries, and the proper safety precautions. • Be very careful when working with large lead-acid batteries. Wear eye protection and have fresh water available in case there is contact with the battery acid. •...

  • Page 6: Getting Started

    Getting Started 2.1 Overview Thank you for selecting the TriStar MPPT 150V solar charge controller with TrakStar MPPT Technology. The TriStar MPPT 150V (TS-MPPT) is an advanced maximum power point tracking operation at the solar array peak power point, maximizing energy harvest. The TriStar MPPT 150V battery charging process has been optimized for long battery life and improved system performance.
  • Page 7 Power connection for Battery (+) 5 - Remote Temperature Sensor Terminals Connection point for a Morningstar RTS (optional) to remotely monitor battery temperature 6 - LED Indicators Three state of charge (SOC) LED indicators show charging status and controller faults...

  • Page 8: Optional Accessories

    • DIN rail compatible or surface mount For more information on the Relay Driver, visit our website at www.morningstarcorp.com or in- quire with your local Morningstar dealer. EIA-485 / RS-232 Communications Adapter (RSC-1) Connect one or more TriStar MPPT 150V controllers to a PC or to other serial devices using the RSC-1 EIA-485 adapter.

  • Page 9: Installation

    Installation 3.1 General Information 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 a sealed enclosure. The controller may be mounted in an enclosure with sealed batteries, but the TriStar MPPT 150V circuits.

  • Page 10: Controller Installation

    3.2 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 TriStar MPPT 150V 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 11 Step 3 - Mount to a Vertical Surface CAUTION: Risk of Burns Install the TriStar MPPT 150V in a location that prevents casual contact. The TriStar MPPT 150V heatsink can become very hot during operation. M6 Screw Mounting Hanger Figure 3-2. Attaching the mounting hanger 1.
  • Page 12 Switches 4, 5, & 6: Battery Charging Settings It is important to select the battery type that matches the system battery to ensure proper charg- Settings Battery Absorp. Float Equalize Equalize Switches Type Stage Stage Stage Interval 4 - 5 - 6 (Volts) (Volts) (Volts)

  • Page 13: Step 5 - Remote Temperature Sensor

    Step 5 - Remote Temperature Sensor The included Remote Temperature Sensor (RTS) is recommended for effective temperature com- pensated charging. Connect the RTS to the 2-position terminal located between the battery (+) (0.34 mm ) cable. There is no polarity, so either wire (+ or -) can be connected to either screw terminal.

  • Page 14: Step 8 - Network Connections

    Step 7 - Battery Voltage Sense The voltage at the battery connection on the TriStar MPPT 150V may differ slightly from the volt- age directly at the battery bank terminals due to connection and cable resistance. The Battery Voltage Sense connection enables the TriStar MPPT 150V to measure the battery terminal volt- age precisely with small gauge wires that carry very little current, and thus have no voltage drop.
  • Page 15 RS-232 Connection is recommended to save room in the wiring box. NOTE: The RS-232 and EIA-485 ports share hardware. Both ports cannot be used simultaneously. REMARQUE : Les ports RS-232 et EIA-485 partagent le matériel. Ils ne peuvent pas être utilisés simultanément.
  • Page 16 Disconnects WARNING: Shock Hazard Fuses, circuit breakers, and disconnect switches should never open grounded system conductors. Only GFDI devices are permitted to disconnect grounded conductors. AVERTISSEMENT : Risque de décharge électrique Les fusibles, coupe-circuits et interrupteurs ne doivent jamais ouvrir les conducteurs du système mis à...
  • Page 17 WARNING: Risk of Damage Be very certain that the solar connection is made with correct polarity. Turn on the solar array breaker/disconnect and measure the voltage on the open wires BEFORE connecting to the TriStar MPPT 150V. Disconnect the solar breaker/ disconnect before wiring to the controller.

  • Page 18: Operation

    TriStar MPPT 150V as described in this section. 4.1 TrakStar MPPT Technology The TriStar MPPT 150V utilizes Morningstar’s TrakStar Maximum Power Point Tracking (MPPT) technology to extract maximum power from the solar array. The tracking algorithm is fully automatic and does not require user adjustment.

  • Page 19: Battery Charging Information

    4.2 Battery Charging Information 4-Stage Charging battery charging. Figure 4-2 shows the sequence of the stages. BULK NIGHT FLOAT ABSORPTION NIGHT CHARGE TIME Figure 4-2. TriStar MPPT 150V Charging Algorithm Bulk Charge Stage In Bulk charging stage, the battery is not at 100% state of charge and battery voltage has not yet charged to the Absorption voltage set-point.
  • Page 20 voltages, and complete the chemical reactions. Equalize charging raises the battery voltage above the standard absorption voltage so that the electrolyte gases. The green SOC LED will blink rapidly two (2) times per second during equalization charging. The duration of the equalize charge is determined by the selected battery type. See table 4-1 in this section for more details.
  • Page 21 The TriStar MPPT 150V provides seven (7) standard battery charging settings that are selectable with the settings DIP switches (see Figure 4.1 above). These standard charging settings are suitable for lead-acid batteries ranging from sealed (gel, AGM, maintenance-free) to Flooded and L-16 cells.

  • Page 22: Temperature Compensation

    Equalize Time-out Bulk Equalize Float Equalize V Absorp. V Equalize timeout time (hrs) 1:00 2:00 3:00 4:00 5:00 6:00 Equalize Timeout event. The timeout timer begins as current or system loads are too large, the battery voltage may not reach the Equalize setpoint. Equalize Timeout is a safety feature that prevents high battery voltage for extended periods of time which may damage the battery.

  • Page 23: Led Indications

    REMARQUE : Avec plusieurs contrôleurs TriStar MPPT 150V sur un réseau MeterBusTM, initialisez une contrôleurs. Note that if two or more TriStar MPPT 150V controllers are charging in parallel, each controller may attempt to equalize on a different day. Systems with multiple controllers should only equalize manually to ensure synchronization between controllers.
  • Page 24 diagnostics that report Fault and Alarm conditions as they occur. Faults are events or conditions that require the TriStar MPPT 150V to cease operation. A Fault usually occurs when a limit such as voltage, current, or temperature has been surpassed. Fault conditions are indicated with unique LED sequences and are also displayed on the TriStar Meter.
  • Page 25 The Remote Temperature Sensor is not connected to the controller. Use of the RTS is recom- mended for proper battery charging. 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 26: Maintenance Items

    Schedule Maintenance Items Re-tighten power terminal connections to specified torque 2 weeks after installation values. Re-tighten power terminal connections to specified torque 3 months after installation values. Inspect the battery bank. Look for cracked or Monthly or After Each bulging cases, and corroded terminals. Equalization is correct.

  • Page 27: Morningstar Meterbus

    • communicate with a Relay Driver or other compatible Morningstar accessories (see sec- tion 2.5 for more details) **A Morningstar MeterBus Hub (HUB-1) and either a TriStar Digital Meter 2 (TS-M-2) or TriStar Remote Meter 2 (TS-RM-2) are required, not included.
  • Page 28 PC (or other serial device). Firmware updates can only be programmed through the RS-232 connection. The serial connection is not typically used for multi-controller networking. However, networking is possible using a USB hub and USB-Serial cables. For more information, refer to the “Morningstar Communications Document” on our website at: www.morningstarcorp.com Networking and Communication...

  • Page 29: Network Information

    • • monitor and receive messages on an SNMP network This section provides a summary of each of the features. For detailed information about Ethernet connectivity and networking, refer to the “Morningstar Communications Document” on our web- site at: HTTP://www.morningstarcorp.com/...

  • Page 30: View Logged Data

    Email & SMS Alerts of the following occurs: • TriStar MPPT 150V self diagnostics fault condition • TriStar MPPT 150V self diagnostics alarm condition • MSView TriStar MPPT 150V wizard. View Logged Data The TriStar MPPT 150V logs up to 200 days* of daily data. The controller always logs the stan- al values each day.

  • Page 31: Network And Communication Issues

    • A serial cross-over (Null Modem) cable is used for the connection between the PC and the Morningstar RSC-1 485 Adapter. A straight-through serial cable will not work. • Power is supplied to the 4-wire bus on the Power/Ground lines. The bus requires voltage in the range: 8 - 16 Vdc.

  • Page 32: Warranty Claim Procedure

    1. Before proceeding, please refer to product manual, including troubleshooting section. 2. Contacting your authorized Morningstar distributor or dealer from whom you purchased the unit is 3. If supplier is unable to address the issue, please contact Morningstar by e-mail (support@morn- ingstarcorp.com) with:...
  • Page 33 Battery Charging Status LEDs LED Indication Battery Charging Status Green Flashing (fast) - 2.5 times per second Equalize charging stage Green Flashing - 1/2 sec on, 1/2 sec off Absorption charging stage Green Flashing (slow) - 1 sec on, 1 sec off Float charging stage Green Green &...
  • Page 34 TriStar MPPT 12 Volt Efficiency 13 Vmp 16.5 Vmp 66 Vmp 98 Vmp output power (Watts) TriStar MPPT 24 Volt Efficiency 26 Vmp 33 Vmp 66 Vmp 98 Vmp 1000 1100 1200 1300 1400 1500 output power (Watts)
  • Page 35 2% Voltage Drop Charts for 75°C Stranded Copper Wire 1-Way Wire Distance (feet), 12 Volt System Wire Size (AWG) Amps Amps Amps Amps Amps Amps Amps Amps Amps Amps 2/0 ** 22.4 24.4 26.9 29.9 33.6 38.4 44.8 53.8 67.2 89.6 1/0 ** 17.8...
  • Page 36 2% Voltage Drop Charts for 90°C Stranded Copper Wire 1-Way Wire Distance (feet), 12 Volt System Wire Size (AWG) Amps Amps Amps Amps Amps Amps Amps Amps Amps Amps 2/0 ** 22.4 24.4 26.9 29.9 33.6 38.4 44.8 53.8 67.2 89.6 1/0 ** 17.8...
  • Page 37 THIS PAGE IS LEFT BLANK INTENTIONALLY...

This manual is also suitable for:

Tristar ts-mppt-45Tristar ts-mppt-60Tristar ts-mppt-30

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