Morningstar TRAKSTAR MPPT 600V Manual
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Morningstar TRAKSTAR MPPT 600V Manual

Morningstar TRAKSTAR MPPT 600V Manual

Solar battery charger
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TM
T
S
RI
TAR MPPT 600V
Solar Charging System Controller
Installation, Operation and Maintenance Manu al
For the most recent manual revision, 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
TS-MPPT-60-600V-48-DB
MAXIMUM POWER POINT TRACKING

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  • Page 1 TAR MPPT 600V Solar Charging System Controller Installation, Operation and Maintenance Manu al For the most recent manual revision, 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 TS-MPPT-60-600V-48-DB MAXIMUM POWER POINT TRACKING...

  • Page 2: Table Of Contents

     4.4 LED Indications       4.5 Protections, Faults & Alarms 5.0 Networking and Communications 5.1 Introduction 5.2 Morningstar MeterBus  5.3 Serial RS-232  5.4 EIA-485 (formerly RS-485)     5.5 Ethernet ...

  • Page 3: Important Safety Instructions

    1.0 Important Safety Instructions Table of Contents (Cont.) SAVE THESE INSTRUCTIONS. This manual contains important safety, installation and operating instructions for the 6.0 Troubleshooting TriStar MPPT 600V solar controller. The following symbols are used throughout this manual to indicate potentially dangerous conditions or mark important safety instructions: 6.1 Battery Charging and Performance Issues 6.2 Network and Communications Issues WARNING:...
  • Page 4 Informations de Sécurité • This charge controller is to be connected to DC circuits only. These DC connections are identified by the symbol below: • Lisez toutes les instructions et les avertissements figurant dans le manuel avant de com- mencer l’installation. •...
  • Page 5 • Ce contrôleur de charge ne doit être connecté qu’à des circuits en courant continu. Ces connex- • Servicing of batteries should be performed, or supervised, by personnel knowledgeable about ions CC sont identifiées par le symbole ci-dessous: batteries, and the proper safety precautions. •...

  • 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

    2.4 Features NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protec- The features of the TS-MPPT-60-600V-48 model are shown in Figure 2-1 below. An explanation tion against harmful interference in a residential installation.
  • Page 8 12 - Battery Negative Power Terminal Negative terminal for negative battery cable termination 13 - Remote Temperature Sensor Terminals Connection point for a Morningstar RTS to remotely monitor battery temperature 14 - Wiring Box Cover Sheet metal wiring box cover protects power connections...
  • Page 9 7 - Serial RS-232 Port 23 - Remote Temperature Sensor Terminals 9-pin serial connector (female) Connection point for a Morningstar RTS to remotely monitor battery temperature 8 - EIA-485 Port 24 - LED Indicators Four (4) position screw terminal for EIA-485 bus connections...

  • Page 10: Installation

    2.5 Accessories Installation The accessories described below are available for purchase separately from your authorized Morningstar dealer. Please see the individual product manuals for installation and operation details. 3.1 General Information Ground Fault Protection Device (GFPD-600V) The GFPD detects power source ground faults and disconnects the as required by the U.S.

  • Page 11: Wiring Zones

    Recommended Tools: • Wire strippers • Pliers • Wire cutters • Drill3/32” (2.5 mm) drill bit • #2 & #0 Phillips screwdriver • Level • slotted screwdrivers • hack saw (cutting conduit) 3.2 Wiring Zones The 600V solar circuits must be separated from the low voltage battery circuits and communica- tion wiring within the wiring box.

  • Page 12: Conduit Knock-Outs And Wiring Routing

    3.3 Conduit Knock-outs and Wire Routing Knock-outs are provided for routing cables through conduit or wire glands. Table 3-1 details the knock-out sizes and quantity provided on the TriStar MPPT 600V wiring box. Knockout place- ment dimensions are on the inside front cover. Figures 3-2 to 3-5 show knock-out types. The TriStar MPPT 600V wiring box provides continuous and separate paths for high voltage (solar) and low voltage (battery &...

  • Page 13: Controller Preparation

    Use a #2 Phillips screw driver to remove the four (4) screws that secure the wiring box cover as shown in figure 3-7 below. Communication Wiring Battery Wiring Solar Wiring Figure 3-6. Wiring pass-through paths between multiple controllers Figure 3-7. Remove the wiring box cover Step 2 - Remove the Wiring Divider (TS-MPPT-60-600-V48 and TS-MPPT-60- 3.4 Controller Preparation (TS-MPPT-60-600V-48 and 600V-48-DB) and Solar Terminal Bridge (TS-MPPT-60-600V-48 ONLY)

  • Page 14: Mounting

    Step 3 - Remove the Knock-Outs Plan the routing of each cable that will connect to the TriStar MPPT 600V before removing any knock-outs. The 1/2” (M20) knock-outs are ideal for routing network cables, which must be placed in separate conduit from power conductors. Use a flat head screwdriver to remove the necessary knock-outs.

  • Page 15: Network Connections

    5. Insert a #10 screw (included) into the top pilot hole. Do not tighten the screw completely. Leave a 1/4” (6 mm) gap between the mounting surface and screw head. 6. Carefully align the keyhole on the TriStar MPPT 600V with the screw head. Slide the TriStar MPPT 600V down over the keyhole.

  • Page 16: Wiring Connections

    RS-232 Connection The serial RS-232 port is a standard 9-pin (DB9) female connector. A low-profile serial connector 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.
  • Page 17 Minimum Wire Size (Field Wiring Connections Only) The NEC requires that the wires carrying the system current never exceed 80% of the conductor's current rating. Table 3.2 below provides the minimum size of copper wire for battery output connections allowed by NEC for both TriStar MPPT 600V models when the output current equals the full nameplate rating.
  • Page 18 5. Connect the solar (-) wire to the solar (-) terminal on the TriStar MPPT 600V. AVERTISSEMENT: Risque d’endommagement Assurez-vous que la connexion solaire est effectuée avec la polarité correcte. Activez le coupe-circuit/ 6. Replace the Wiring Divider (removed in Step 2 on page 24) over the solar wires, and secure it interrupteur de réseau solaire et mesure la tension sur les câbles ouverts AVANT la connexion au TriStar with the M4 screw provided.
  • Page 19 3. Only route high voltage solar circuit conductors in the high voltage wiring zone and low Step 7 - Remote Temperature Sensor voltage battery and network conductors within the low voltage zone. Refer to section 3.2 for The included Remote Temperature Sensor (RTS) is recommended for effective temperature more information.

  • Page 20: Configuration

    AVERTISSEMENT : Risque D'incendie Switches 4, 5, & 6: Battery Charging Settings Lors de la connexion des câbles de détection de batterie, installez un fusible de 5 A dans le fil It is important to select the battery type that matches the system battery to ensure proper charg- de détection (+), six pouces de la borne (+) de la batterie.

  • Page 21: Grounding, Power-Up (And Power-Down)

    (GFPD). The TriStar MPPT 600V does not have internal CAUTION: Risk of Tampering ground fault protection, but Morningstar Corporation offers an accessory GFPD-600V. The The Ethernet Security settings switch does not block write commands to devices bridged via system electrical negative should be bonded through a GFPD to earth ground at one (and only EIA-485.

  • Page 22: Operation

    La connexion du réseau solaire ou la connexion de la batterie avec une polarité inversée endommagera le TriStar MPPT 600V 600Vde façon permanente. The TriStar MPPT 600V utilizes Morningstar’s TrakStar Maximum Power Point Tracking • Confirm that the solar and battery polarities are correct.

  • Page 23: Battery Charging Information

    4.2 Battery Charging Information Float Stage After the battery is fully charged in the Absorption stage, the TriStar MPPT 600V reduces the 4-Stage Charging battery voltage to the Float voltage set-point. When the battery is fully recharged, there can be no more chemical reactions and all the charging current is turned into heat and gassing.
  • Page 24 Certain battery types benefit from a periodic boost charge to stir the electrolyte, level the cell volt- Preparation for Equalization ages, and complete the chemical reactions. Equalize charging raises the battery voltage above First, confirm that all of the system loads are rated for the equalization voltage. Consider that at the standard absorption voltage so that the electrolyte gasses.
  • Page 25 Battery Charging Settings Absorption Extension Extended The details of the TriStar MPPT 600V battery charging settings are shown in tables 4-1 and 4-2 Absorption below. All voltage settings listed are for nominal 48 Volt battery banks. Bulk Absorption Float Settings Battery Absorp.
  • Page 26 Float Cancel Voltage Temperature Compensation Bulk Absorption All charging settings are based on 25°C (77°F). If the battery temperature varies by 5°C, the charging setting will change by 0.60 Volts for a 48 Volt battery. This is a substantial change in the charging of the battery, and the use of the Remote Temperature Sensor (RTS) is recom- mended to adjust charging to the actual battery temperature.

  • Page 27: Push-Button

    4.3 Push-button 4.4 LED Indications The following functions can be enabled with the pushbutton (located on the front cover): Valuable information is provided by the three LEDs visible through the front cover. Although there are many different LED indications, they have similar patterns to make it easier to interpret each LED PUSH display.

  • Page 28: Protections, Faults & Alarms

    4.5 Protections, Faults & Alarms Battery State-of-Charge LED Indications 80% to 95% SOC The TriStar MPPT 600V protections and automatic recovery are important features that ensure G / Y 60% to 80% SOC the safe operation of the system. Additionally, the TriStar MPPT 600V features real-time self 35% to 60% SOC diagnostics that report Fault and Alarm conditions as they occur.
  • Page 29 After all settings have been modified, the controller must be reset by The heatsink temperature sensor is damaged. Return the controller to an authorized Morningstar removing and then restoring power to the controller. The new programmed settings will be used dealer for service.

  • Page 30: Networking And Communications

    RS-232, EIA-485, and Ethernet. MSView PC software is available for free on our website at: **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).

  • Page 31: Serial Rs-232

    USB hub and USB-Serial cables. For more information, refer to • log real-time data with MSView PC software the “Morningstar Communications Document” on our website at: • configure Ethernet settings • update controller firmware with MSLoad firmware utility http://morningstarcorp.com/support...

  • Page 32: Eia-485 (Formerly Rs-485)

    • program each controller on the network with custom charge settings using MSView internet. software • connect the TriStar MPPT 600V to other Morningstar controllers with the RSC-1 Serial to Some of the features the Ethernet connection provides include: EIA-485 Adapter (sold separately) •...
  • Page 33 The TriStar MPPT 600V 600VSetup Wizard in MSView provides an interface to adjust all oper- ating parameters. Morningstar’s MSView PC software can connect to any TriStar MPPT 600V on the Ethernet network or through a RS-232 serial connection. Refer to the help documentation included with MSView for more information.

  • Page 34: Troubleshooting

    16* vdc or greater. If the voltage on the battery terminals of the controller OID. is between 16 and 72 vdc, and no LEDs are lit, contact your authorized Morningstar dealer for GET NEXT service. If no voltage is measured, check wiring connections, fuses, and breakers.

  • Page 35: Network And Communications 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 36: Maintenance And Service

    Maintenance and Service • External solar and battery disconnects are required. • Disconnect all sources of power to the controller before installing or adjusting the TriStar MPPT 600V. • There are no fuses or disconnects inside the TriStar MPPT 600V Do not attempt to repair. 7.1 Important Safety Instructions Informations de Sécurité...
  • Page 37 • Do not smoke near the battery bank. • Utilisez des conducteurs et des coupe-circuits de dimensions adaptées. • Power connections must remain tight to avoid excessive heating from a loose connection. • La borne de mise à la terre se trouve dans le compartiment de câblage et est identifiée par le symbole ci-dessous estampillé...

  • Page 38: Maintenance Schedule

    CAUTION: When replacing batteries, proper specified number, sizes types and ratings • Débrancher la source de charge avant de brancher ou dis-reliant les bornes de la batterie. based on application and system design • Utilisez des outils isolés et évitez de placer des objets métalliques dans la zone de travail. •...

  • Page 39: Warranty And Claim Procedure

    Warranty on replaced units, or field-replaced components, will be limited only to the duration of the original product coverage. Inspect the battery bank. Look for cracked or bulging cases, and Morningstar will, at its option, repair or replace any such defective units. corroded terminals. Monthly or After Each...

  • Page 40: Technical Specifications

    WARRANTY CLAIM PROCEDURE Electrical 1. Before proceeding, please refer to product manual, including troubleshooting section. TS-MPPT-60-600V-48 TS-MPPT-60-600V-48-DB 2. Contacting your authorized Morningstar distributor or dealer from whom you purchased the unit is Nominal System Voltage 48 Volts 48 Volts the first step in the warranty process. Local dealers can often address warranty issues quickly.
  • Page 41 Battery Charging Status LEDs Environmental LED Indication Battery Charging Status Operating Altitude Below 2000 meters Green Flashing (fast) - 2 to 3 times per second Equalize charging stage Ambient Temperature Range -40°C to +45°C Green Flashing - once per second Absorption charging stage Storage Temperature -55°C to +85°C...

  • Page 42: Appendix

    10.0 Appendix Battery Current vs. Heatsink Temperature De-ratings Battery Current vs. Array Voltage Array Voltage (Volts) Heatsink Temperature (degrees Figure 10-2. Battery Current vs. Heatsink Temperature Array Voltage (Volts) Figure 10-1. Battery Current vs. Array Voltage 10.0 Appendix TriStar MPPT 600V Operator’s Manual...
  • Page 43 Efficiency Output Power vs. Array Input Voltage 200 Vmp, 52 Vbatt 60 Amp Battery Current Limit Vb = 60 V 3500 60 Amp Battery Current Limit 3000 Vb = 50 V 2500 60 Amp Battery Current Limit Vb = 40 V 300 Vmp, 52 Vbatt 2000 60 Amp Battery Current Limit...
  • Page 44 2% Voltage Drop Charts for 75°C Stranded Copper Wire 2% Voltage Drop Charts for 75°C Solid 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 2% Voltage Drop Charts for 90° Stranded Copper Wire 2% Voltage Drop Charts for 90°C Solid 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 46: Certifications

    Under, “Type”, choose, “Declaration of Conformity (DOC)”, to view list of product DOCs. TrisStar MPPT , MeterBus are trademarks of Morningstar Corporation MODBUS and MODBUS TCP/IP are trademarks of Modbus IDA. www.modbus-ida.org © 2022 Morningstar Corporation. All rights reserved. MS-000962 v6.6 Certifications...

This manual is also suitable for:

Trakstar ts-mppt-60-600v-48Trakstar ts-mppt-60-600v-48-db

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