TM Solar Charging System Controller Installation, Operation and Maintenance Manual For the most recent manual revisions, see the version at: www.morningstarcorp.com MAXIMUM POWER POINT TRACKING ..... Solar Battery Charging ..... Load Control ..... Diversion Control www.morningstarcorp.
Table of Contents Important Safety Instructions................................................................... 1 1.0 TriStar Description............................................................................ 7 1.1 Versions and Ratings...................................................................... 7 1.2 Operating Modes........................................................................ 7 1.3 Adjustability................................................................................
5.0 6.0 Load & Lighting Control................................................................ 42 5.1 General Load & Lighting Control Notes............................................42 5.1.1 Inductive Loads............................................................. 42 5.1.2 Parallel TriStars....................................................................42 5.1.3 Reverse Polarity...................................................................42 5.2 Load Control Settings.......................
WARNING: RISK OF ELECTRICAL SHOCK. NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROM DC INPUT, AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN FAULT CONDITIONS, BATTERY COULD BECOME OVER-CHARGED. TEST BETWEEN ALL TERMINALS AND GROUND BEFORE TOUCHING. • External solar and battery disconnects are required. • Disconnect all sources of power to the controller before installing or adjusting the TriStar-PWM.
le fonctionnement. • Utilisez des outils isolés pour travailler avec les batteries. • Évitez le port de bijoux pendant l’installation. • Le groupe de batteries doit être constitué de batteries du même type, fabricant et âge. PRUDENCE: Lorsque le remplacement des piles, utilisez correctement nombre spécifié, tailles, types et les évaluations basées sur conception de système et d’application. CAUTION: Do not open or mutilate batteries. Released electrolyte is harmful to skin, and may be toxic.
• Soyez très prudent quand vous travaillez avec des grandes batteries au plomb. Portez des lunettes de protection et ayez de l’eau fraîche à disposition en cas de contact avec l’électrolyte. • Enlevez les montres, bagues, bijoux et autres objets mé talliques avant de travailler avec des piles. • Porter des bottes et des gants de caoutchouc 1.0 TriStar Description The TriStar is a technically advanced solar system controller. There are three operating modes programmed into each TriStar.
1.3 Adjustibility 1.
1.5 1.6 NOTE: This section contains important information for safety and regulatory requirements. Remote Temperature Sensor (RTS) If the temperature of the system battery varies more than 5˚C (9˚F) during the year, temperature compensated charging should be considered. Because the battery’s chemical reactions change with temperature, it can be important to adjust charging to account for the temperature effects.
2.2 The installation is straightforward, but it is important that each step is done correctly and safely. A mistake can lead to dangerous voltage and current levels. Be sure to carefully follow each instruction in Section 2.3 and observe all cautions and warnings. The installation instructions describe solar battery charging. Specific instructions for the load control and diversion modes are provided as notes.
Recommended tools: • wire cutter • torque wrench (to 50 in-lb) Hydro — Wind — Solar + + – – +– Battery + Source + Battery – Sense Diversion – + Battery – Source – Diversion + Figure 2.2b Installation Wiring for Diversion Charge Control NOTE: TriStar negative terminals are common negative. Steps #3 and #6 are required for all installations. Steps #4, #5, and #7 are optional. Step Diversion Charge Control 1. Remove the access cover 2. Mount the TriStar using the enclosed template. 3.
REMARQUE : Les instructions ci-dessous concernent la charge de batteries solaires. Reportez-vous à l’Annexe 1 pour les réglages du commutateur DIP de contrôle de charge et à l’Annexe 2 pour les réglages du commutateur DIP de contrôle de charge de diversion. ON ON DIP 260.4 (10.25) OFF 189.7 (7.47) 3 4 5 6 7 8 System Voltage (2,3) 45.7 (1. 80) 25.4 (1.00) Battery Charging Algorithm (4,5,6) 16.8 (0.66) 41.9 (1.65) 85.1 (3.35) 110.5 (4. 35) 127.0 (5.00) Figure 2.
The DIP switch settings described below are for Solar Battery Charging only. Load and Diversion switch settings can be found in Appendixes 1 and 2. The DIP switches are shipped in the OFF position. With the switches in the OFF position, the following functions are present: Function Battery charge mode Auto voltage select Lowest battery charging voltage Manual equalization Normal PWM charging mode ON Figure 2.
Select one of the 7 standard battery charging algorithms, or select the “custom” DIP switch for special custom settings using the PC software. Refer to Section 9.0 of this manual for battery charging information. The 7 standard charging algorithms above are described in Section 4.2 Standard Battery Charging Programs. ON ON DIVERSION CHARGE CONTROL DIP switch settings are in Appendix 2. NOTE: Confirm all dip-switch settings before going to the next installation steps.
AVERTISSEMENT: Risque d’incendie. Si non Capteur de température distant (RTS) est connecté, utilisez le TriStar-PWM 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. REMARQUE : Ne placez jamais la sonde de température dans un élément de batterie. Le RTS et la batterie seraient endommagés.
NOTES: • The specified wire length is for a pair of conductors from the solar, load or battery source to the controller (1-way distance). • Figures are in meters (m) and feet (ft). • For 24 volt systems, multiply the 1-way length in the table by 2. • For 48 volt systems, multiply the 1-way length in the table by 4. + CAUTION: The solar PV array can produce open-circuit voltages over 100 Vdc when in sunlight.
Do not bend the power wires up toward the access cover. If a TS-M meter is used now or in the future, these large wires can damage the meter assembly when the access cover is attached to the controller. 3.0 TriStar Operation The TriStar operation is fully automatic. After the installation is completed, there are few operator tasks to perform. However, the operator should be familiar with the basic operation and care of the TriStar as described below. Torque each of the four power terminals to 5.
3.3 LED Indications Valuable information can be provided by the three LEDs in 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 or Load Status // Faults. LOAD & LIGHTING CONTROL 2.
REMARQUE : Il existera toujours un délai de 10 secondes entre les tentatives de reconnexion des commutateurs TEC. Même si l’alimentation est déconnectée, le TriStar attend la fin des 10 secondes quand l’alimentation est rétablie. Solar overload: (R/Y-G sequencing) If the solar input exceeds 100% of the controller’s current rating, the controller will reduce the average current below the TriStar’s rating. The controller is capable of managing up to 130% of the rated solar input.
Remote temperature sensor (RTS) failure: (R/Y-G/Y) If a fault in the RTS (such as a short circuit, open circuit, loose terminal) occurs after the RTS has been working, the LEDs will indicate a failure and the solar input is disconnected. However, if the controller is restarted with a failed RTS, the controller may not detect that the RTS is connected, and the LEDs will not indicate a problem. A TriStar meter or the PC software can be used to determine if the RTS is working properly.
4.0 Battery Charging 4.1 Battery Voltage Sense: Connecting a pair of voltage sense wires from the controller to the battery is recommended. This allows a precise battery voltage input to the controller and more accurate battery charging. See Section 4.3 for PWM Battery Charging more information. PWM (Pulse Width Modulation) battery charging is the most efficient and effective method for recharging a battery in a solar system. Refer to “Why PWM?” on Morningstar’s website for more information.
A. Battery Type - These are generic lead-acid battery types. See Section 9.0 for more information about battery types and appropriate solar charging. B. PWM Voltage–This is the PWM Absorption stage with constant voltage charging. The “PWM voltage” is the maximum battery voltage that will be held constant. As the battery becomes more charged, the charging current tapers down until the battery is fully charged. C. Float Voltage–When the battery is fully charged, the charging voltage will be reduced to 13.
These voltage drops will cause some undercharging of the battery. The controller will begin PWM absorption, or limit equalization, at a lower battery voltage because the controller measures a higher voltage at the controller’s terminals than is the actual battery voltage. For example, if the controller is programmed to start PWM absorption at 14.4V, when the controller “sees” 14.4V at its battery terminals, the true battery voltage would only be 14.1V if there is a 0.
4.4.3 Preparation for Equalization First, confirm that all your loads are rated for the equalization voltage. Consider that at 0˚C (32˚F) the equalization voltage will reach 16.05V in a 12V system (64.2V in a 48V system) with a temperature sensor installed. Disconnect any loads at risk. If Hydrocaps are used, be sure to remove them before starting an equal ization. Replace the Hydrocaps with standard battery cell caps. The Hydro caps can get very hot during an equalization.
5.0 Load and Lighting Control 5.1 General Load & Lighting Control Notes IMPORTANT: 5.1.1 Inductive loads Do not connect inductive loads such as inverters, motors, pumps, compressors, generators to the load terminals. Inductive loads can generate large voltage spikes that may damage the controller’s lightning protection devices. Connect inductive loads directly to the battery. If a heavy load must be connected to the TriStar's load terminals e.g.
After an LVD, the load reconnect voltages are 0.25 volts per battery cell higher than the LVD (for example, in a 12V system the LVD would be 1.5 volts above LVD). Battery voltages can rise quickly after an LVD, typically from 1.0 to 1.3 volts or more (12V system). The LVD value must be high enough to avoid cycling in and out of LVD. As the battery charges, the diversion duty cycle will increase. When fully charged, all the source energy will flow into the diversion load if there are no other loads.
All values are @25ºC (77ºF). A. B. DIP Switches (4-5-6) PWM Absorp. Float Voltage Voltage C. D. E. F. G. Time Max. Until Time Equalize Equalize Float Equalization in Equal. Interval Cycle (hours) Voltage (hours) (days) (hours) off-off-off 13.8 13.6 4 14.1 3 28 off-off-on 14.0 13.6 4 14.3 3 28 off-on-off 14.2 13.6 4 14.5 3 28 off-on-on 14.4 13.6 4 14.7 4 28 on-off-off 14.6 13.7 4 14.9 4 28 on-off-on 14.8 13.7 4 15.1 4 28 on-on-off 15.0 13.7 4 15.
NOTE: Because the battery can supply any size load, the peak load current is not limited by the source (hydro or wind rating). The diversion load’s power rating is the critical specification for reliable battery charging. REMARQUE : La batterie pouvant fournir une charge de n’importe quelle dimension, le pic d’intensité de la charge n’est pas limité par la source (puissance hydro ou éolienne).
The minimum diversion load would be the source output (35A) times the voltage (30V). This would require a 1,050 watt heating element rated at 30 volts. Or if a 2,000W heater element rated for 120 volts is used, 9 heater elements will be required to draw the required minimum diversion load at 30 volts. 6.5 7.0 Custom Settings with PC Software An RS-232 connection between the TriStar and an external personal computer (PC) allows many set-points and operating parameters to be easily adjusted.
7.3 8.0 Self-Test / Diagnostics Changing Set-points Follow the instructions in the PC software. CAUTION: There are few limits to the changes that can be made. It is the responsibility of the operator to be certain all changes are appropriate. Any damage resulting to the controller or the system from TriStar setpoint adjustments will not be covered under warranty. PRUDENCE : Les modifications pouvant être effectuées sont sujettes à quelques limites.
8.2 Troubleshooting Solar Charging 9.0 Battery Information • Over-charging or under-charging the battery • DIP switch settings may be wrong •R TS is not correcting for high or low temperatures • Over-temperature condition is reducing the charging current (heat sink cooling may be blocked — indicated with LEDs) • Voltage drop between TriStar and battery is too high (connect the battery The standard battery charging programs in the TriStar controller, as described in Section 4.
is important to never exceed the manufacturer’s maximum charging voltages. Typically, a gel battery is recharged in cycling applications from 14.1V to 14.4V. The gel design is very sensitive to overcharging. Lead-Antimony: Antimony cells are rugged and provide long service life with deep discharge capability. However, these batteries self-discharge much faster and the selfdischarging increases up to five times the initial rate as the battery ages. Charging the antimony battery is typically from 14.
10.0 Warranty 11.0 Technical Specifications LIMITED WARRANTY Morningstar TriStar-PWM ELECTRICAL • System voltage ratings 12, 24, 48 Vdc • Current ratings — Solar Input TS-45: TS-60/M: The TriStar-PWM is warrantied to be free from defects in material and workmanship for a period of FIVE (5) years from the date of shipment to the original end user. Morningstar will, at its option, repair or replace any such defective products.
BATTERY CHARGING STATUS LEDs G 13.3 to PWM G/Y 13.0 to 13.3 V Y 12.65 to 13.0 V Y/R 12.0 to 12.65 V R 0 to 12.0 V Note: Multiply x 2 for 24V systems, x 4 for 48V systems Note: The LED indications are for charging a battery. When discharging, the LEDs will typically be Y/R or R.
The DIP switch settings described below are for Load and Lighting Control only. The DIP switches are shipped in the OFF position. The OFF settings will operate as follows: Switch 1 2, 3 4, 5, 6 7 8 Function The DIP switch selectable voltages are for 12V, 24V or 48V lead-acid batteries. Although the “auto voltage” selection is very dependable, it is recommended to use the DIP switches to secure the correct system voltage.
DIP Switches Number 4,5,6 - Lighting Control Algorithm: For Lighting Control mode, set the DIP switches 4,5,& 6 according to the table below.
the ON position, Diversion Charge Contol is set.
DIP Switches Number 4,5,6 - Diversion Charge Control: Battery Type PWM Switch 4 Switch 5 Switch 6 1 13.8 Off Off Off 2 14.0 Off Off On 3 14.2 Off On Off 4 14.4 Off On On 5 14.6 On Off Off 6 14.8 On Off On 7 15.0 On On Off 8 Custom On On On ON ON DIP DIV 13.8V ON DIP Switch Number 8 - Battery Equalization: Equalize Switch 8 Manual Off Auto On 1 2 3 4 5 6 7 8 ON DIV 14.
Appendix 3 - LED Indications 3. Faults & Alarms LED Display Explanation: G = green LED is lit Y = yellow LED is lit R = red LED is lit G/Y = Green and Yellow are both lit at the same time G/Y - R = Green & Yellow both lit, then Red is lit alone Sequencing (faults) has the LED pattern repeating until the fault is cleared 1.
12.0 Certifications ALL COMPONENTS ® TUVRheinland REACH COMPLIANT CERTIFIED Registration, Evaluation and Authorization of Chemicals THIS PAGE IS LEFT BLANK INTENTIONALLY • Complies with ETL UL 1741 and cETL CSA-C22.2 No. 107.
