TRISTAR MPPT TM Solar System Controller Installation and Operation Manual Solar Battery Charger with TrakStar TM Maximum Power Point Tracking Technology 8 Pheasant Run Newtown, PA 18940 USA email: info@morningstarcorp.com www.morningstarcorp.
Dimensions in Inches [Millimeters]
Contents 1.0 Important Safety Information 2.0 Getting Started 2.1 Overview 2.2 Versions and Ratings 2.3 Features 2.4 Regulatory Information 2.5 Optional Accessories 3.0 Installation 4 8 8 8 9 11 12 13 3.1 General Information 13 3.2 Controller Installation 15 4.0 Operation 4.1 TrakStarTM MPPT Technology 4.2 Battery Charging Information 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.
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 conditions or mark important safety instructions: WARNING: Indicates a potentially dangerous condition. Use extreme caution when performing this task. ! CAUTION: Indicates a critical procedure for safe and proper operation of the controller.
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 water to enter the controller. • Use insulated tools when working with batteries. • Avoid wearing jewelry during installation.
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. • Utilisez des outils isolés pour travailler avec les batteries. • Évitez le port de bijoux pendant l’installation.
About this Manual This manual provides detailed installation and usage instructions for the TriStar MPPT controller. Only qualified 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.
2.0 Getting Started 2.1 Overview Thank you for selecting the TriStar MPPT solar charge controller with TrakStarTM MPPT Technology. The TriStar MPPT (TS-MPPT) is an advanced maximum power point tracking solar battery charger. The controller features a smart tracking algorithm that finds and maintains operation at the solar array peak power point, maximizing energy harvest. The TriStar MPPT battery charging process has been optimized for long battery life and improved system performance.
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.
1 - Heatsink Aluminum heatsink to dissipate controller heat 2 - Mounting Hanger Keyhole slot for mounting 3 - Settings Switches Eight (8) settings switches to configure operation of the TriStar MPPT 4 - Battery Positive Terminal (red) 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 7 -
2.4 Regulatory Information NOTE: This section contains important information for safety and regulatory requirements. The TriStar MPPT controller should be installed by a qualified technician according to the electrical rules of the country in which the product will be installed.
2.5 Optional Accessories The following accessories are available for purchase separately from your authorized Morningstar dealer. TriStar Digital Meter 2 / TriStar Remote Meter 2 (Models: TS-M-2 / TS-RM-2) The TriStar Digital Meter mounts directly on the TS-MPPT controller, replacing the wiring box cover. The TriStar Remote Meter can be flush mounted in a wall or into a standard duplex (2gang) electrical box.
3.0 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 installed in a ventilated enclosure with sufficient air flow. Never install the TriStar MPPT in a sealed enclosure. The controller may be mounted in an enclosure with sealed batteries, but never with vented/flooded batteries.
Recommended Tools: • Wire strippers • Wire cutters • #2 & #0 Phillips screwdriver • slotted screwdrivers • Pliers • Drill • 3/32” (2.
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.
Step 2 - Remove the knockouts Knockouts are provided for routing cables through conduit or wire glands. Table 3-1 below provides 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 8 1/2” or M20 7/8” (22.2 mm) 6 1“ 1 - 23/64 “ (34.5 mm) 4 1 - 1/4 “ 1 - 23/32 “ (43.7 mm) Table 3-1.
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 figure 3-2. 2. Place the TriStar MPPT on a vertical surface protected from direct sun, high temperatures, and water. The TriStar MPPT requires at least 6” (150 mm) of clearance above and below and at least 1” (25 mm) on each side for proper air flow as shown in figure 3-3 below. Figure 3-3.
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. Remove the controller and drill 3/32” (2.5 mm) holes at the drill marks. 10. Carefully align the keyhole on the TriStar MPPT with the screw head. Slide the TriStar MPPT down over the keyhole. 11. The pre-drilled pilot holes should align with the mounting holes in the wiring box.
Switches 4, 5, & 6: Battery Charging Settings It is important to select the battery type that matches the system battery to ensure proper charging and long battery life. Refer to the specifications provided by the battery manufacturer and choose a setting that best fits the recommended charging profile. Settings Switches 4-5-6 Battery Type Absorp. Stage (Volts) Float Stage (Volts) Equalize Stage (Volts) Equalize Interval (Days) off-off-off 1 - Gel 14.00 13.70 off-off-on 2 - Sealed* 14.15 13.
Equalize Switch 7 manual OFF automatic ON Switch 8: Ethernet Security The Ethernet Security switch enables or disables configuration 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.
Step 5 - Remote Temperature Sensor The included Remote Temperature Sensor (RTS) is recommended for effective temperature compensated charging. Connect the RTS to the 2-position terminal located between the pushbutton and the LED’s (see figure 2-1). The RTS is supplied with 33 ft (10 m) of 22 AWG (0.34 mm2) cable. There is no polarity, so either wire (+ or -) can be connected to either screw terminal. The RTS cable may be pulled through conduit along with the power wires.
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. NOTE: Conductors identified by the color combination green/yellow shall only be used for earthing conductors. AVERTISSEMENT : L’appareil n’est pas fourni avec un dispositif GFDI.
Step 7 - Battery Voltage Sense The voltage at the battery connection on the TriStar MPPT may differ slightly from the voltage directly 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.
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 wiring box on the lower circuit board as shown in figure 3-5. Figure 3-5.
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. Ils ne peuvent pas être utilisés simultanément. Ethernet Connection The RJ-45 Ethernet jack features two (2) indicator LEDs for connection status and network traffic.
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.
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 la terre. Seuls les dispositifs GFDI sont autorisés à déconnecter les conducteurs reliés mis à la terre.
Figure 3-7. Power terminal locations Connect the four (4) power conductors shown in figure 3-7 above in the following steps: 1. Confirm 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. 2. Provide for strain relief if the bottom knockouts are used and conduit is not used. 3. Pull the wires into the wiring box.
AVERTISSEMENT : Risque d’endommagement Assurez-vous que la connexion solaire est effectuée avec la polarité correcte. Activez le coupecircuit/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. 6. Connect the Solar + (positive) wire to the Solar + terminal on the TriStar MPPT. The Solar + terminal has a yellow cover. 7.
4.0 Operation The TriStar MPPT operation is fully automatic. After installation is completed, there are few operator tasks to perform. However, the operator should be familiar with the operation and care of the TriStar MPPT as described in this section. 4.1 TrakStarTM MPPT Technology The TriStar MPPT utilizes Morningstar’s TrakStarTM 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.
An Advantage Over Traditional Controllers Traditional controllers connect the solar module directly to the battery when recharging. This requires that the solar module operate in a voltage range that is usually below the module’s Vmp. In a 12 Volt system for example, the battery voltage may range from 10 - 15 Vdc, but the module’s Vmp is typically around 16 or 17 Volts. Figure 4-1 shows typical current vs. voltage and power output curves for a nominal 12 Volt off-grid module. 12 Volt Module Current vs.
4.2 Battery Charging Information 4-Stage Charging The TriStar MPPT has a 4-stage battery charging algorithm for rapid, efficient, and safe battery charging. Figure 4-2 shows the sequence of the stages. VOLTAGE EQUALIZE NIGHT BULK CHARGE ABSORPTION FLOAT 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.
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 float stage provides a very low rate of maintenance charging while reducing the heating and gassing of a fully charged battery. The purpose of float is to protect the battery from long-term overcharge.
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 defined as time spent at the equalize setpoint. If there is insufficient charge current to reach the equalization voltage, the equalization will terminate after an additional 60 minutes to avoid over gassing or heating the battery.
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 equalization. Also, if Hydrocaps are used, the equalization should be set for manual only (DIP switch #7 is Off). After the equalization is finished, add distilled water to each cell to replace gassing losses. Check that the battery plates are covered.
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 Switches 4-5-6 off-off-off Battery Type 1 - Gel Absorp. Stage (Volts) Float Stage (Volts) 14.00 13.70 Equalize Stage (Volts) Absorp.
Absorption Extension Figure 4-3. Absorption extension charging profile. If battery voltage discharges below 12.50 Volts (25.00 Volts @ 24 V, 50 Volts @ 48 V) the previous night, Absorption charging will be extended on the next charge cycle as shown in figure 4-3 above. 30 minutes will be added to the normal Absorption duration. Float Timeout Figure 4-4.
Float Cancel Voltage Figure 4-5. Float cancelled charging profile 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. At 0:00 hrs (dawn), battery voltage is below the Float Cancel threshold voltage. The diagram shows where Float stage would have occurred if Float was not cancelled. Equalize Timeout Figure 4-6.
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 recommended to adjust charging to the actual battery temperature. The need for temperature compensation depends on the temperature variations, battery type, how the system is used, and other factors.
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 flashing LED’s will stop blinking. If the battery service is performed before the LED’s begin blinking, the pushbutton must be pushed at the time when the LED’s are blinking to reset the service interval and stop the blinking.
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 & Alarms.
Battery State-of-Charge LED Indications G G+Y Y Y+R R 80% to 95% SOC 60% to 80% SOC 35% to 60% SOC 0% to 35% SOC battery is discharging Refer to the Specifications (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 designs, they are only approximate indications of the battery charge state.
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. A Fault usually occurs when a limit such as voltage, current, or temperature has been surpassed.
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 controller 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. A TriStar meter or the PC software can be used to determine if the battery sense is working properly.
Current Limit The array power exceeds the rating of the controller. This alarm indicates that the TriStar MPPT is limiting battery current to the maximum current rating. RTS Open The Remote Temperature Sensor is not connected to the controller. Use of the RTS is recommended 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.
4.6 Inspection and Maintenance The following inspections are recommended two times per year for best long-term performance. System Inspection • Confirm the controller is securely mounted in a clean and dry environment. • Confirm that the air flow around the controller is not blocked. Clean the heat sink of any dirt or debris. • Inspect all exposed conductors for insulation damage due to sun damage, rubbing on nearby objects, dry rot, insects, or rodents. Repair or replace conductors as necessary.
5.0 Networking and Communication 5.1 Introduction The TriStar MPPT provides several communication options. The TriStar MPPT uses a proprietary protocol for the MeterBusTM network and the non-proprietary open standard MODBUSTM and MODBUS TCP/IPTM protocols for RS-232, EIA-485, and ethernet networks. Additionally, HTTP, SMTP, and SNMP are supported for web page, email, and network message support.
5.2 Morningstar MeterBusTM Morningstar’s proprietary MeterBusTM protocol allows communication between compatible Morningstar products. Use a MeterBusTM network to: • display net system data for multiple TriStar / TriStar MPPT systems** • communicate with a TriStar Digital Meter 2 or TriStar Remote Meter 2 • communicate with a Relay Driver or other compatible Morningstar accessories (see section 2.
5.3 Serial RS-232 The serial port connection on the TriStar MPPT is a standard 9-pin isolated RS-232 port. See figure 3-5 for the port location.The TriStar MPPT communicates through the serial port via the open standard MODBUSTM protocol.
Serial Port Settings Adjust the serial port settings as follows: • 9600 BAUD • 8 data bits • 1 or 2 stop bits • no parity The serial RS-232 connection provides a direct connection between a TriStar MPPT and a 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.
5.4 EIA-485 (formerly RS-485) NOTE: The EIA-485 connection is only available on the TS-MPPT-60 model. NOTE: The RS-232 and EIA-485 ports share hardware. Both ports cannot be used simultaneously. EIA-485 is a networking standard for serial communication between multiple devices on a bus. The TriStar MPPT communicates over an EIA-485 network via the open standard MODBUSTM protocol.
5.5 Ethernet NOTE: Ethernet is only available on the TS-MPPT-60 model. ! CAUTION: Risk of Tampering The TS-MPPT does not feature built-in network security. It is the responsibility of the user or network administrator to place the TS-MPPT behind a network firewall to prevent unauthorized access. ! PRUDENCE : Risque de tentative d’altération Le TS-MPPT ne comporte pas de sécurité réseau intégrée.
Factory Default Network Settings DHCP Live View Web Address IP Subnet Mask Gateway Primary DNS Server MODBUS TCP/IPTM Port enabled http://tsmppt + serial number ** 192.168.1.253 (if DHCP is not enabled) 255.255.255.0 192.168.1.1 169.254.1.1 502 ** The Live View web address is unique to each controller. If the TriStar MPPT serial number is 09501234, then the Live View address is: http://tsmppt09501234. The Live View address is printed on the serial label on the side of the unit for reference.
Email & SMS Alerts The email and SMS alerts feature sends notification 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 • User-defined event (e.g. battery voltage is less than 46 Volts) Up to four email and SMS alerts can be configured from the network settings web page in the MSView TriStar MPPT wizard. View logged data The TriStar MPPT logs up to 200 days* of daily data.
6.0 Troubleshooting Battery Charging and Performance Issues Problem: No LED indications, controller does not appear to be powered Solution: With a multi-meter, check the voltage at the battery terminals on the TriStar MPPT. Battery voltage must be 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.
Problem: Cannot connect to the controller via EIA-485 Solution: Check the following: • The RS-232 port is not in use. The EIA-485 and RS-232 ports cannot be used simultaneously. Only one port can be used at a time. • The RSC-1 adapter used to connect the PC to the EIA-485 network shows a green LED and pulses red when a connection is attempted. See the RSC-1 documentation for more information. • Each controller or device on the EIA-485 network has been programmed with a unique MODBUS ID.
7.0 Warranty The TriStar MPPT charge controller is warranted 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. CLAIM PROCEDURE Before requesting warranty service, check the Operator’s Manual to be certain that there is a problem with the controller.
8.0 Specifications Electrical TS-MPPT-45 TS-MPPT-60 12, 24, 36, or 48 Volts dc Nominal System Voltage 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 24 Volt 1200 Watts 1600 Watts 48 Volt 2400 Watts 3200 Watts Voltage Accuracy 12 / 24 V: ≤ 0.1 % ± 50 mV 48 V: ≤ 0.1 % ± 100 mV Self consumption (tare loss) 1.3 - 2.
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 ≤ Vbattery Green & Yellow 13.0 Volts ≤ Vbattery < 13.3 Volts Yellow 12.7 Volts ≤ Vbattery < 13.0 Volts Yellow & Red 12.0 Volts ≤ Vbattery < 12.7 Volts Red Vbattery < 12.
Deratings Figure 8-7. Battery Current vs. Array Voltage Figure 8-8. Battery Current vs.
Efficiency TriStar MPPT 12 Volt Efficiency 98 97 13 Vmp 96 16.5 Vmp efficiency (%) 95 66 Vmp 94 93 98 Vmp 92 91 90 89 88 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 output power (Watts) Battery @ 12.8 V, 25 C ambient, firmware ver.
TriStar MPPT 48 Volt Efficiency 100 52 Vmp 99 66 Vmp 83 Vmp 98 Vmp 98 efficiency (%) 97 96 95 94 93 92 91 90 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 output power (Watts) Battery @ 51.2 V, 25 C ambient, firmware ver.
Certifications UL1741 INVERTERS, CONVERTERS, AND CONTROLLERS AND INTERCONNECTION SYSTEM RoHS EQUIPMENT FOR USE WITH DISTRIBUTED ENERGY SOURCES, FIRST EDITION, REVISION THROUGH AND INCLUDING NOV 7, 2005 3094762 CSA C22.2 No. 107.
2% Voltage Drop Charts for 75°C Stranded Copper Wire 1-Way Wire Distance (feet), 12 Volt System Wire Size (AWG) 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 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 19.4 21.3 23.7 26.6 30.4 35.5 42.6 53.3 71.0 2 11.2 12.2 13.4 14.9 16.8 19.1 22.3 26.8 33.5 44.7 4 7.0 7.7 8.4 9.4 10.6 12.1 14.1 16.9 21.1 28.1 6 4.4 4.8 5.3 5.9 6.6 7.6 8.8 10.6 13.
2% Voltage Drop Charts for 75°C Solid Copper Wire 1-Way Wire Distance (feet), 12 Volt System Wire Size (AWG) 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 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 24.1 26.5 29.4 33.1 37.8 44.1 52.9 66.1 88.2 2 13.9 15.1 16.6 18.5 20.8 23.8 27.7 33.3 41.6 55.4 4 8.7 9.5 10.5 11.6 13.1 14.9 17.4 20.9 26.2 34.9 6 5.5 6.0 6.6 7.3 8.2 9.4 11.0 13.2 16.
2% Voltage Drop Charts for 90°C Stranded Copper Wire 1-Way Wire Distance (feet), 12 Volt System Wire Size (AWG) 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 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 19.4 21.3 23.7 26.6 30.4 35.5 42.6 53.3 71.0 2 11.2 12.2 13.4 14.9 16.8 19.1 22.3 26.8 33.5 44.7 4 7.0 7.7 8.4 9.4 10.6 12.1 14.1 16.9 21.1 28.1 6 4.4 4.8 5.3 5.9 6.6 7.6 8.8 10.6 13.
2% Voltage Drop Charts for 90°C Solid Copper Wire 1-Way Wire Distance (feet), 12 Volt System Wire Size (AWG) 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 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 24.1 26.5 29.4 33.1 37.8 44.1 52.9 66.1 88.2 2 13.9 15.1 16.6 18.5 20.8 23.8 27.7 33.3 41.6 55.4 4 8.7 9.5 10.5 11.6 13.1 14.9 17.4 20.9 26.2 34.9 6 5.5 6.0 6.6 7.3 8.2 9.4 11.0 13.2 16.
TriStarTM, TriStar MPPTTM, MeterBusTM are trademarks of Morningstar Corporation MODBUSTM and MODBUS TCP/IPTM are trademarks of Modbus IDA. www.modbus-ida.org RoHS © 2010 Morningstar Corporation. All rights reserved.
