Morningstar TriStar TS-MPPT-60M Installation And Operation Manual

Solar battery charger with trakstar maximum power point tracking technology

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TAR MPPT

Solar System Controller

Installation and Operation Manual

Solar Battery Charger

with

TrakStar

Maximum Power Point Tracking Technology

8 Pheasant Run

Newtown, PA 18940 USA

email: info@morningstarcorp.com

www.morningstarcorp.com

Models

TS-MPPT-60

TS-MPPT-45

MAXIMUM POWER POINT TRACKING

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Summary of Contents for Morningstar TriStar TS-MPPT-60M

Page 1 TAR MPPT Solar System Controller Installation and Operation Manual Solar Battery Charger with TrakStar Maximum Power Point Tracking Technology 8 Pheasant Run Newtown, PA 18940 USA email: info@morningstarcorp.com www.morningstarcorp.com Models TS-MPPT-60 TS-MPPT-45 MAXIMUM POWER POINT TRACKING...
Page 2 Dimensions in Inches [Millimeters]...
Page 3: Table Of Contents
4.3 Push button 4.4 LED Indications 4.5 Protections, Faults & Alarms 4.6 Inspection and Maintenance 5.0 Networking and Communication 5.1 Introduction 5.2 Morningstar MeterBus 5.3 Serial RS-232 5.4 EIA-485 (formerly RS-485) 5.5 Ethernet 6.0 Troubleshooting 7.0 Warranty 8.0 Speciﬁ cations...
Page 4: Important Safety Information
1.0 Important Safety Information Save These Instructions This manual contains important safety, installation and operating instructions for the TriStar MPPT solar controller. The following symbols are used throughout this manual to indicate potentially dangerous condi- tions or mark important safety instructions: WARNING: Indicates a potentially dangerous condition.
Page 5 Installation Safety Precautions WARNING: This unit is not provided with a GFDI device. This charge controller must be used with an external GFDI device as required by the Article 690 of the National Electrical Code for the installation location. • Mount the TriStar MPPT indoors. Prevent exposure to the elements and do not allow wa- ter to enter the controller.
Page 6 AVERTISSEMENT : L’appareil n’est pas fourni avec un dispositif GFDI. Ce contrôleur de charge doit être utilisé avec un dispositif GFDI externe tel que requis par l’Article 690 du Code électrique national de l’emplacement de l’installation. • Montez le TriStar MPPT à l’intérieur. Empêchez l’exposition aux éléments et la pénétration d’eau dans le contrôleur.
Page 7 About this Manual This manual provides detailed installation and usage instructions for the TriStar MPPT controller. Only qualiﬁ ed electricians and technicians who are familiar with solar system design and wiring practices should install the TriStar MPPT. The usage information in this manual is intended for the system owner/operator.
Page 8: Getting Started
Getting Started 2.1 Overview Thank you for selecting the TriStar MPPT solar charge controller with TrakStar MPPT Technol- ogy. The TriStar MPPT (TS-MPPT) is an advanced maximum power point tracking solar battery charger. The controller features a smart tracking algorithm that ﬁ nds and maintains operation at the solar array peak power point, maximizing energy harvest.
Page 9: Features
2.3 Features The features of the TriStar MPPT are shown in Figure 2-1 below. An explanation of each feature is provided. Figure 2-1. TriStar MPPT features TriStar MPPT Operator’s Manual...
Page 10 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 11: Regulatory Information
(2) this device must accept any interference received, including interference that may cause undesired operation. Changes or modiﬁ cations not expressly approved by Morningstar for compliance could void the user’s authority to operate the equipment.
Page 12: 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 controllers to a PC or to other serial devices using the RSC-1 EIA-485 adapter.
Page 13: 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 in- stalled in a ventilated enclosure with sufﬁ cient air ﬂ ow. Never install the TriStar MPPT in a sealed enclosure.
Page 14 Recommended Tools: • Wire strippers • Wire cutters • #2 & #0 Phillips screwdriver • slotted screwdrivers • Pliers • Drill • 3/32” (2.5 mm) drill bit • Level • hack saw (cutting conduit) Installation...
Page 15: 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 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 16 Step 2 - Remove the knockouts Knockouts are provided for routing cables through conduit or wire glands. Table 3-1 below pro- vides the knockout sizes and quantity on the TriStar MPPT wiring box. Knockout locations and dimensions are on the inside front cover. Quantity Trade Size Hole Dimension...
Page 17 Step 3 - Mount to a Vertical Surface Figure 3-2. Attaching the mounting hanger 1. Attach the mounting hanger to the bottom of the TriStar MPPT with the M6 screw provided as shown in ﬁ gure 3-2. 2. Place the TriStar MPPT on a vertical surface protected from direct sun, high temperatures, and water.
Page 18 6. Carefully align the keyhole on the TriStar MPPT with the screw head. Slide the TriStar MPPT down over the keyhole. 7. Check for vertical plumb with a level. 8. Mark two (2) mounting hole locations in the wiring box. 9.
Page 19 Switches 4, 5, & 6: Battery Charging Settings It is important to select the battery type that matches the system battery to ensure proper charg- ing and long battery life. Refer to the speciﬁ cations provided by the battery manufacturer and choose a setting that best ﬁ...
Page 20 Equalize Switch 7 manual automatic Switch 8: Ethernet Security The Ethernet Security switch enables or disables conﬁ guration of the TriStar MPPT settings through the Ethernet connection. When switch eight is set to disabled, write commands to the TriStar MPPT custom memory are not allowed. This a safety feature to prevent unintended changes to custom settings, but it is not a replacement for proper network security.
Page 21 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 pushbut- ton and the LED’s (see ﬁ gure 2-1). The RTS is supplied with 33 ft (10 m) of 22 AWG (0.34 mm cable.
Page 22 Step 6 - Grounding and Ground Fault Interruption WARNING: This unit is not provided with a GFDI device. This charge controller must be used with an external GFDI device as required by the Article 690 of the National Electrical Code for the installation location.
Page 23 Step 7 - Battery Voltage Sense The voltage at the battery connection on the TriStar MPPT may differ slightly from the voltage di- rectly at the battery bank terminals due to connection and cable resistance. The Battery Voltage Sense connection enables the TriStar MPPT to measure the battery terminal voltage precisely with small gauge wires that carry very little current, and thus have no voltage drop.
Page 24 AVERTISSEMENT : Risque de décharge électrique N’utilisez qu’un câble de communication 300 V homologué UL. Connect the appropriate network cables to the TriStar MPPT at this time. Access to the network ports is easier before the power cables are attached. The ports are located inside the conduit wir- ing box on the lower circuit board as shown in ﬁ...
Page 25 RS-232 Connection The serial RS-232 port is a standard 9-pin (DB9) female connector. A low-proﬁ le 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 26 Step 9 - Power Connections NOTE: To comply with the NEC, the TriStar MPPT must be installed using wiring methods in accordance with the latest edition of the National Electric Code, NFPA 70. CAUTION: Risk of Fire and Shock Connect battery terminals prior to the connection of array terminals. The battery positive (+) terminal has a red cover, the solar positive (+) terminal has a yellow cover.
Page 27 Overcurrent Protection and 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 28 Figure 3-7. Power terminal locations Connect the four (4) power conductors shown in ﬁ gure 3-7 above in the following steps: 1. Conﬁ rm that the system input and output disconnect switches are both turned off before connecting the power wires to the controller. There are no disconnect switches inside the TriStar MPPT.
Page 29 AVERTISSEMENT : Risque d’endommagement Assurez-vous que la connexion solaire est effectuée avec la polarité correcte. Activez le coupe- circuit/interrupteur de réseau solaire et mesure la tension sur les câbles ouverts AVANT la connexion au TriStar MPPT. Déconnectez le coupe-circuit/interrupteur solaire avant le câblage sur le contrôleur.
Page 30: Operation
TriStar MPPT as described in this section. 4.1 TrakStar MPPT Technology The TriStar MPPT utilizes Morningstar’s TrakStar Maximum Power Point Tracking technology to extract maximum power from the solar array. The tracking algorithm is fully automatic and does not require user adjustment. TrakStar...
Page 31 An Advantage Over Traditional Controllers Traditional controllers connect the solar module directly to the battery when recharging. This re- quires that the solar module operate in a voltage range that is usually below the module’s V . In a 12 Volt system for example, the battery voltage may range from 10 - 15 Vdc, but the module’s is typically around 16 or 17 Volts.
Page 32: Battery Charging Information
4.2 Battery Charging Information 4-Stage Charging The TriStar MPPT has a 4-stage battery charging algorithm for rapid, efﬁ cient, and safe battery charging. Figure 4-2 shows the sequence of the stages. EQUALIZE ABSORPTION FLOAT BULK CHARGE NIGHT NIGHT TIME Figure 4-2. TriStar MPPT 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 setpoint.
Page 33 Float Stage After the battery is fully charged in the Absorption stage, the TriStar MPPT reduces the battery voltage to the Float voltage setpoint. When the battery is fully recharged, there can be no more chemical reactions and all the charging current is turned into heat and gassing. The ﬂ oat stage provides a very low rate of maintenance charging while reducing the heating and gassing of a fully charged battery.
Page 34 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. The Equalization Time is deﬁ ned as time spent at the equalize setpoint.
Page 35 If Hydrocaps are used, be sure to remove them before starting an equalization. Replace the Hydrocaps with standard battery cell caps. The Hydrocaps can get very hot during an equaliza- tion. Also, if Hydrocaps are used, the equalization should be set for manual only (DIP switch #7 is Off).
Page 36 Battery Charging Settings The details of the TriStar MPPT battery charging settings are shown in tables 4-1 and 4-2 below. All voltage settings listed are for nominal 12 Volt batteries. Multiply the voltage settings by two (2) for 24 Volt batteries or by four (4) for 48 Volt systems. Settings Battery Absorp.
Page 37 Absorption Extension Figure 4-3. Absorption extension charging proﬁ le. If battery voltage discharges below 12.50 Volts (25.00 Volts @ 24 V, 50 Volts @ 48 V) the previ- ous night, Absorption charging will be extended on the next charge cycle as shown in ﬁ gure 4-3 above.
Page 38 Float Cancel Voltage Figure 4-5. Float cancelled charging proﬁ le If the battery bank discharges below 11.50 Volts (23.00 Volts @ 24 V, 46.00 Volts @ 48 V) the previous night, Float charging stage will be cancelled for the next charge cycle. Figure 4-5 above illustrates this concept.
Page 39 Temperature Compensation All charging settings are based on 25°C (77°F). If the battery temperature varies by 5°C, the charging setting will change by 0.15 Volts for a 12 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 40: Push Button
4.3 Push button The following functions can be enabled with the pushbutton (located on the front cover): PUSH • Reset from an error or fault. • Reset the battery service indication if this has been activated in custom settings. A new service period will be started, and the ﬂ...
Page 41: Led Indications
4.4 LED Indications Valuable information can be provided by the three LED’s visible through the front cover. Although there are many different LED indications, they have similar patterns to make it easier to interpret each LED display. Consider as three groups of indications: General Transitions // Battery Status // Faults &...
Page 42 Battery State-of-Charge LED Indications 80% to 95% SOC 60% to 80% SOC 35% to 60% SOC 0% to 35% SOC battery is discharging Refer to the Speciﬁ cations (Section 8.0) for the State-of-Charge voltages. Note that because these State-of-Charge LED displays are for all battery types and system de- signs, they are only approximate indications of the battery charge state.
Page 43: Protections, Faults & Alarms
4.5 Protections, Faults & Alarms The TriStar MPPT protections and automatic recovery are important features that ensure the safe operation of the system. Additionally, the TriStar MPPT features real-time self diagnostics that report Fault and Alarm conditions as they occur. Faults are events or conditions that require the TriStar MPPT to cease operation.
Page 44 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 LED’s will indicate a failure. If the control- ler is restarted with the failure still present, the controller may not detect that the battery sense is connected and the LED’s will not indicate a fault.
Page 45 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 46: Inspection And Maintenance
4.6 Inspection and Maintenance The following inspections are recommended two times per year for best long-term performance. System Inspection • Conﬁ rm the controller is securely mounted in a clean and dry environment. • Conﬁ rm that the air ﬂ ow around the controller is not blocked. Clean the heat sink of any dirt or debris.
Page 47: Networking And Communication
MODBUS TCP/IP protocols for RS-232, EIA-485, and ethernet networks. Additionally, HTTP, SMTP, and SNMP are supported for web page, email, and network message support. Morningstar’s MSView PC software provides system monitoring and logging capabilities via RS-232, EIA-485, and ethernet. MSView PC software is available for free on our website at: http://www.morningstarcorp.com.
Page 48: 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 49: Serial Rs-232
5.3 Serial RS-232 The serial port connection on the TriStar MPPT is a standard 9-pin isolated RS-232 port. See ﬁ g- ure 3-5 for the port location.The TriStar MPPT communicates through the serial port via the open standard MODBUS protocol. Connect the TriStar MPPT to the serial port on a PC to: •...
Page 50 (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: HTTP://www.morningstarcorp.com/ Networking and Communication...
Page 51: Eia-485 (Formerly Rs-485)
• program each controller on the network with custom charge settings using MSView software • connect the TriStar MPPT to other Morningstar controllers with the RSC-1 Serial to EIA- 485 Adapter (sold separately) • bridge an Ethernet connection through a TriStar MPPT to an EIA-485 network The EIA-485 port has four (4) connections: Power, Data A, Data B, and Ground.
Page 52: Ethernet
• send an email or text message if a fault, alarm, or user-deﬁ ned event occurs • 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 53 The TriStar MPPT Setup Wizard in MSView provides an interface to adjust all operating param- eters. Morningstar’s MSView PC software can connect to any TriStar MPPT on the Ethernet network or through a RS-232 serial connection. Refer to the help documentation included with MSView for more information.
Page 54 Email & SMS Alerts The email and SMS alerts feature sends notiﬁ cation to an email address or mobile phone if one of the following occurs: • TriStar MPPT self diagnostics fault condition • TriStar MPPT self diagnostics alarm condition •...
Page 55: Troubleshooting
8 Vdc or greater. If the voltage on the battery terminals of the controller is between 8 and 72 Vdc and no LEDs are lit, contact your authorized Morningstar dealer for service. If no voltage is measured, check wiring connections, fuses, and breakers.
Page 56 • 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 57: Warranty
This information is critical to a rapid disposition of your warranty claim. Morningstar will pay the return shipping charges if the repairs are covered by the warranty. WARRANTY EXCLUSIONS AND LIMITATIONS This warranty does not apply under the following conditions: •...
Page 58: Specifi Cations
8.0 Speciﬁ cations Electrical TS-MPPT-45 TS-MPPT-60 Nominal System Voltage 12, 24, 36, or 48 Volts dc Maximum Battery Current 45 Amps 60 Amps Maximum Solar Input Voltage 150 Volts dc Battery Operating Voltage Range 8 - 72 Volts dc Nominal Maximum Input Power: 12 Volt 600 Watts 800 Watts...
Page 59 Battery Charging Status LEDs LED Indication Battery Charging Status Green Flashing (fast) - 2 to 3 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 13.3 Volts ≤...
Page 60 Deratings Figure 8-7. Battery Current vs. Array Voltage Figure 8-8. Battery Current vs. Heatsink Temperature Speciﬁ cations...
Page 61 Effi ciency TriStar MPPT 12 Volt Efficiency 13 Vmp 16.5 Vmp 66 Vmp 98 Vmp output power (Watts) Battery @ 12.8 V, 25 C ambient, ﬁ rmware ver. 08 or later TriStar MPPT 24 Volt Efficiency 26 Vmp 33 Vmp 66 Vmp 98 Vmp 1000 1100 1200 1300 1400 1500...
Page 62 TriStar MPPT 48 Volt Efficiency 52 Vmp 66 Vmp 83 Vmp 98 Vmp 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 output power (Watts) Battery @ 51.2 V, 25 C ambient, ﬁ rmware ver. 08 or later Speciﬁ...
Page 63 Certifi cations RoHS UL1741 INVERTERS, CONVERTERS, AND CONTROLLERS AND INTERCONNECTION SYSTEM EQUIPMENT FOR USE WITH DISTRIBUTED ENERGY SOURCES, FIRST EDITION, REVISION THROUGH AND Compliant INCLUDING NOV 7, 2005 CSA C22.2 No. 107.1-01 2002/95/EC 3094762 EMC Directives • Immunity: EN61000-6-2:1999 • Emissions: EN55022:1994 with A1 and A3 Class B1 •...
Page 64 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 65 2% Voltage Drop Charts for 75°C Solid 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 ** 27.8 30.3 33.4 37.1 41.7 47.7 55.6 66.7 83.4 111.2 1/0 ** 22.0...
Page 66 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 67 2% Voltage Drop Charts for 90°C Solid 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 ** 27.8 30.3 33.4 37.1 41.7 47.7 55.6 66.7 83.4 111.2 1/0 ** 22.0...
Page 68 TriStar , TriStar MPPT , MeterBus are trademarks of Morningstar Corporation MODBUS and MODBUS TCP/IP are trademarks of Modbus IDA. www.modbus-ida.org RoHS For product and purchase inquiries contact: © 2010 Morningstar Corporation. All rights reserved. www.ecodirect.com MS-ZMAN-TSMPPT-01 03/2010...

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