Installation Manual

24 TRISTAR INSTALLATION 25 MORNINGSTAR CORPORATION
2.0
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.
The NEC requires that manually operated disconnect switches or circuit
breakers must be provided for connections between the TriStar and the
battery. If the overcurrent devices being used are not manually operated
disconnects, then manual disconnect switches must be added. These manual
switches must be rated the same as the overcurrent devices noted above.
•
Refer to the NEC for more information.
Minimum Wire Size
The NEC requires that the wires carrying the system current never exceed
80% of the conductors’ current rating. The table below provides the minimum
size of copper wire allowed by NEC for the TS-45 and TS-60 versions. Wire
types rated for 75˚C and 90˚C are included.
Minimum wire sizes for ambient temperatures to 45˚C are provided in the
table below:
TS-45 75C Wire 90C Wire TS-60 75C Wire 90C Wire
≤ 45C 16 mm
2
(6 AWG) 10 mm
2
(8 AWG) ≤ 45C 25 mm
2
(4 AWG) 16 mm
2
(6
AWG)
Table 2.3-6b Minimum Wire Size
Both copper and aluminum conductors can be used with a TriStar controller. If
aluminum wire is used, the minimum size of the aluminum conductor
must be one wire size larger than the minimum wire size specified in the
table above.
Ground Connection
Use the grounding terminal in the wiring compartment to connect a
copper wire to an earth ground or similar grounding point. The grounding
terminal is identified by the ground symbol shown below that is stamped
into the enclosure:
Ground
Symbol
Per NEC 690.45 (A) and NEC Table 250.122, minimum sizes for copper
grounding wire are:
TS-MPPT-45 10 AWG (5 mm
2
)
TS-MPPT-60/M 8 AWG (8 mm
2
)
OR, of the same, or greater, cross-sectional area as the PV wires.
Connect the Power Wires
First, confirm that the DIP switch #1 is correct for the operating mode
intended.
+
+
–
+
– –
Battery + Battery –
Solar +
Load +
Diversion +
Solar –
Load –
Diversion –
Figure 2.12 - Step 6 Power Wire Connections
CAUTION: The solar PV array can produce open-circuit voltages over 100
Vdc when in sunlight. Verify that the solar input breaker has been opened
(disconnected) before installing the system wires (if the controller is in the
solar charging mode).
PRUDENCE : Le réseau PV solaire peut produire des tensions de circuit
ouvert supérieures à 100 V cc à la lumière du soleil. Vérifiez que le coupe-
circuit solaire a été ouvert (déconnexion) avant d’installer les câbles du
système (si le contrôleur est en mode de charge solaire).
Using the diagram on the previous page, connect the four power conductors
in the following steps:
1. Confirm that the 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.
2. Provide for strain relief if the bottom knockouts are used and conduit is not
used.
3. Pull the wires into the wiring compartment. The temperature probe wires
and battery voltage sense wires can be inside the conduit with the power
conductors.
4. Connect the Battery + (positive) wire to the Battery + terminal.
5. Connect the Battery – (negative) wire to a TriStar common – terminal.
6. Connect the Solar + wire (positive) to the Solar + terminal.
(or Load + / Diversion +)
7. Connect the Solar – (negative) wire a TriStar common – terminal.
(or Load – / Diversion –)
NOTE: TriStar negative terminals are common negative.
The CE certification requires that the battery conductors, the battery voltage
sense wires, and the remote temperature sensor shall not be accessible
without the use of a tool and are protected in the battery compartment.