Morningstar Product Connectivity Manual Networking & Communications 1 September, 2009 8 Pheasant Run Newtown, PA 18940 USA www.morningstarcorp.
Contents 1.0 Introduction 1.1 Communications Protocols 1.2 Communications Interfaces 1.3 RS-232 vs. USB 2.0 Networking Hardware 2.1 Morningstar Equipment 2.2 Other Equipment 3.0 MeterBusTM Networks 3.1 Overview 3.2 Networking Rules 3.3 Example Networks 3.4 Setup Network 4.0 MODBUS Networks 4.1 Overview 4.2 Local Connections 4.3 Remote Connections 5.0 MSView 5.1 Overview 5.2 Installation 5.3 Establishing A Connection 5.4 Creating New Displays 5.5 Setup Wizards 6.0 MSLoad 7.0 Website Hosting via HTTP 8.
11.0 Troubleshooting Appendix I - TSMPPT Networking I. Introduction II. Connect to LAN III. Remote Access IV. Multi-Controller Networking V. Additional Info Appendix II - Advanced System Example General Safety Information: • Only minimal voltages/currents are present in communications circuits, however, it is always necessary to exercise caution when working with electronic circuits. Please observe caution while performing any installation/maintenance outlined in this document.
1.0 Introduction Thank you for choosing Morningstar for your PV control system needs. Morningstar products offer a wide range of networking, logging, data transfer, and custom setting capabilities. Please review this document carefully and become familiar with all the networking/ communication options Morningstar products have to offer. 1.1 Communications Protocols Various protocols are used by Morningstar products to either communicate between Morningstar devices, or with a PC/other 3rd party hardware.
of MODBUSTM transmission exist, ASCII and RTU (remote terminal unit). ! IMPORTANT: Morningstar products are MODBUS devices. RTU For more information into the capabilities of MODBUSTM, please refer to Section 4. 1.1.3 MODBUS TCP/IPTM The MODBUSTM protocol can also be used over IP (Internet Protocol) via an Ethernet connection. MODBUSTM data over IP is identical to MODBUSTM data over serial RS-232, however, it is embedded in data packets characteristic of IP.
1.2 Communications Interfaces The following table outlines the various communications interfaces found on Morningstar products. (Each dot represents one interface.
2.0 Networking Hardware There are many pieces of networking hardware. The following is a description of the most common hardware used to network Morningstar devices. 2.1 Morningstar Equipment 2.1.1 PC MeterBus Adapter (MSC) Figure 1.
The RSC-1 adapter provides the ability to network serial devices over an EIA-485 bus using the MODBUSTM protocol. A null modem cable is used to connect a PC to the RSC-1, while a straightthrough serial cable is used to connect a Morningstar device to the RSC-1. The RSC-1 requires an external power source. Input voltage to the adapter should be between 8-16V, therefore, it may be powered by a 12 Volt battery. Use a DC-DC converter for 24V, 36V, and 48V system batteries.
only a guideline for the user. Morningstar makes no guarantee that these products will interface properly with Morningstar units. Please do all necessary research into compatibility before making a purchase. 2.2.1 Serial (DB-25) / Serial (DB-9) Adapter There are two different types of serial connectors. One has 25 pins and the other (found on Morningstar devices) has 9 pins. Adapters are available to convert 25 pin serial to 9 pin serial.
NOTE: Male/female end connections will vary. Please be sure you purchase a cable with the proper connectors to attach your devices. 2.2.3 Null Modem (Crossover) Cable A null modem serial cable allows two DTE (data terminal equipment) devices to communicate directly without a DCE (data communications equipment) device, such as a modem. The null modem cable connects the Rx (receive) pins to opposing Tx (transmit) pins and CTS (clear to send) pins to their opposing RTS (request to send) pins.
2.2.5 Ethernet Crossover Cable Similar to a null modem cable, an Ethernet crossover cable allows two devices that are normally connected through a hub or a router to communicate directly. When these devices are connected through a hub or router, the crossover is done internally, making a crossover cable unnecessary. Figure 8. Ethernet Crossover Cable NOTE: Both standard and crossover Ethernet cables will vary in color and length. They may look identical on the outside, but internally they are different.
mended for this application. It has been specifically designed to work with Morningstar products. Some 3rd party adapters have been known to either cause problems on the network, or need minor pin modifications to work properly. ! CAUTION: Example: If a converter needs 12V external power in a 24V system, a DC-DC converter should be used. Tapping off individual batteries can cause an imbalanced battery bank. Figure 10.
2.2.9 USB Hub A USB hub allows multiple USB devices to use the same built-in USB port on your PC. There are two types of hubs, bus-powered and self-powered. Bus-powered hubs draw all their power from the PC’s USB port and require devices connected to them to share this power. This often limits the number and types of USB devices which can be connected to the hub. Self-powered, however, uses an external power source to supply full power to every port on the hub. Figure 12.
2.2.11 Ethernet Router Ethernet routers allow you to establish a LAN (local area network), which can then be connected to the Internet. Information sent from a PC or device will have a destination address. It travels to the router, where the router looks up the destination address and forwards it to the appropriate PC or device on the local network. This equipment can be used to connect multiple controllers and a PC over a network and allow them to communicate using the MODBUS IPTM protocol. Figure 14.
Recommended: Digi Connect WAN Family of products (one model shown above) NOTE: Please consult your wireless data provider for information regarding if/how your cellular modem connection will suit your needs and applicable fees. 2.2.13 Point-to-Point Radio (supporting MODBUSTM) These radio systems are used to connect remotely to a device 10-25km away in the field. This type of connection requires a base radio at the PC and a field radio at the device site.
2.2.14 PLC (Programmable Logic Controller) (supporting MODBUSTM) Programmable Logic Controllers can be used as master devices on EIA-485 networks. When multiple controllers are connected over an EIA-485 bus, they are not able to communicate with each other. However, a master device, such as a PLC or PC, is able to poll each controller and retrieve information. Morningstar controllers are MODBUSTM RTU (remote terminal unit) slave devices and can be polled by RTUs and PLCs with MODBUSTM capability.
3.0 MeterBusTM Networking 3.1 Overview The MeterBusTM Protocol is Morningstar’s proprietary messaging structure for communication between Morningstar products. This protocol is used for communications between controllers and meters, controllers and Relay Drivers, and for other inter-product data transfer. Morningstar products supporting this protocol feature RJ-11 ports.
The Meter Hub electrically isolates devices that supply power to the MeterBusTM, preventing grounding problems. (A) Supplies Power (B) Requires Power SunSaver Duo Remote Meter (RM-1) SunSaverMPPT TriStar Digital Meter 2 (TS-M-2) TriStar TriStar Remote Meter 2 (TS-RM-2) TriStarMPPT Relay Driver SureSine Table 2. Morningstar Device MeterBusTM Power Specifications • One device from Table 2, Column A must be connected to Input Power Port B of the Meter Hub.
Figure 17. Morningstar MeterBusTM Small Network Diagram 3.3.2 Example #2 - Medium-Sized Network A typical medium-sized network can be found in Figure 18. This network is comprised of three TriStars, two TS Meters, one Relay Driver, and one Meter Hub. As with the small network, the TS Remote Meter is powered via the TriStar on Input Power Port B. Remember: Only two meters are allowed on a single MeterBusTM network.
3.3.3 Example #3 - RD-1 Polling Network A Relay Driver used in conjunction with a Meter Hub allows the Relay Driver to poll multiple controllers and trigger alarms based upon specific controller inputs. For example, the RD-1 could trigger an alarm for overcurrent on one of the controllers, while simultaneously triggering an alarm for LVD on one of the other controllers. Note that the Relay Driver is connected to Output Power Port A because it does not supply its own power to the MeterBusTM network.
Figure 20. Morningstar MeterBusTM Large, Multiple Hub Network Diagram 1 3.3.5 Example #5 - Large, Multiple Hub Network 2 Device power requirements will sometimes call for a network setup as illustrated in Figure 21. This multiple hub network connects hubs in a different manner than in Example #4.
Figure 21. Morningstar MeterBusTM Large, Multiple Hub Network Diagram 2 NOTE: All networks illustrated above use TriStars to power the network, however, any controller/inverter listed in Table 2, Column A will do the same. 3.4 Setup Your MeterBus Network 3.4.1 Layout and Connections Before you begin physically constructing your MeterBusTM network, make sure you have the proper cables, connectors, adapters, and mounting hardware.
3.4.2 Addressing To enable devices on the network to communicate with each other, each one must be assigned a unique MeterBusTM ID. Only 15 devices are allowed on a single network, therefore, the range of acceptable MeterBusTM IDs is 1 to 15. There are two manners in which you can assign these addresses: using a TS Meter/TS Remote Meter or by using a PC. NOTE: Morningstar recommends using a TS Meter 2/TS Remote Meter 2 for addressing due to its simplicity and speed. 3.4.2.
4.0 MODBUSTM Networking 4.1 Overview MODBUSTM is an open and free communications protocol widely used in industrial automation. It allows for networking of up to 247 devices on a single data link. Setup a MODBUSTM network to: • • • • • program custom charge settings with MSViewTM PC software view real-time data with MSViewTM PC software log real-time data with MSViewTM PC software update controller firmware assign functions to a Relay Driver 4.
4.2.2 USB / Serial (USB / RS-232) To connect the serial RS-232 connection on a Morningstar product to a USB port on a PC, a USB to Serial adapter cable is needed. See Subsection 2.2.8 for a info and a recommendation of a compatible USB to Serial adapter. Figure 23 below illustrates a proper connection. Figure 23. USB / Serial Connection Diagram Once connected, please refer to Section 5 on how to make Local Connections in MSViewTM. 4.2.
Figure 25. USB / RJ-11 Connection Diagram Once connected, please refer to Section 5 on how to make Local Connections in MSViewTM. 4.2.6 Multiple Device Using EIA-485 In an EIA-485 network, each device connects via a serial to EIA-485, 4 wire converter. Each converter, such as Morningstar’s RSC-1 model, is powered by a DC power source. Refer to Section 2.1.2 for more information on the RSC-1 adapter. Power +/- is applied to the adapter as in Figure 26 below.
NOTE: A NULL modem cable is used to connect the PC to the RSC-1 adapter. Once connected, please refer to Section 5 on how to make Local Connections in MSViewTM. 4.2.7 Multiple Device Using USB / RS-232 Multiple devices can be connected to a PC at the same time through the use of a USB / RS-232 network. The USB hub expands the PC’s number of USB ports, allowing for more Morningstar devices to be connected to the computer.
4.3 Remote Connections Remote connections are established between a PC and a device when IP (Internet Protocol) addressing or cellular networks are used. IMPORTANT: The connections described in this section require extensive use of 3rd party hardware, as described in Section 2.2. When interfacing 3rd party hardware with Morningstar products using an RS-232 (serial) connection, it is essential that the proper voltage be applied to the Morningstar unit’s DB-9 pins. Please refer to Section 11.
4.3.2 Point-to-Point Wireless Transfer When a hardwire connection is not feasible, but distances are shorter than would require a cellular connection, point-to-point wireless transfer using radio modems is recommended. Point-topoint wireless can usually cover a distance between 10 and 25 kilometers, however, range will vary depending on the model of radio modem and atmospheric/geographical conditions.
Figure 30. Ethernet Crossover Connection Diagram Once connected, please refer to Section 5 on how to make Remote Connections in MSViewTM. 4.3.3.2 Ethernet to Serial It is possible to connect serially to your controller/inverter using your PC’s Ethernet connection and an Ethernet to serial converter. Although this may appear to be a local connection, it is in fact a remote connection because the Ethernet to serial converter will be assigned an IP address.
In Figure 32, both the PC and the controller have a unique network IP address. The PC can use the controller’s address to poll it for data. Although they are on the same local network, the connection process is very similar to Figure 33 where the PC and controller are connected through the Internet. Controllers that do not have an Ethernet interface can still be connected in this way through the use of an Ethernet to serial converter and (if necessary) a MeterBusTM Adapter (MSC). Figure 32.
a configuration allows for data logging, programming of custom settings, and management of all controllers on the MODBUSTM 485 network. Figure 34 shows a diagram of the proper connections for a remote EIA-485 network when using the TSMPPT. The Ethernet label indicates that any Ethernet communication configuration discussed in this manual is suitable for use with the EIA-485 network. Figure 34. Remote EIA-485 (w/TSMPPT Bridge) Connection Diagram 4.3.
Figure 35.
5.0 MSView 5.1 Overview The MSViewTM software package is used by your PC to update firmware, change custom settings, and view real-time controller data. Configuration wizards make it easy to customize the features of the device, while an intuitive directory tree organization of variables puts real-time data at your fingertips. MSViewTM uses the open-source MODBUSTM protocol described in Subsection 1.1.2.
moments, the MSViewTM software setup wizard should appear. If setup does not begin (or the autorun CD-drive feature has been disabled), run Setup.exe on the CD drive using Windows Explorer. Follow the install wizard instructions. ! IMPORTANT: The software CD provided may not contain the latest version of MSView. Check our website for updates at: http://www.morningstarcorp.com/products/ software 5.2.2 Installation via Internet Download On the Morningstar website (www.morningstarcorp.
USB Connecting via USB requires additional software, usually on a CD that comes with the USB to serial adapter. If you have this CD, run it and install the driver needed to create a Virtual COM Port. If you do not have this CD, the driver usually can be downloaded free from the Internet. Once you have the Virtual COM Port Driver installed, you MAY need to determine which port number the driver has allocated for USB use.
5.5 Setup Wizards MSViewTM provides several Setup Wizards designed to make configuring and customizing your Morningstar product quick and simple. Currently six (6) wizards are available: Relay Driver, SunSaver Duo Setup, SunSaver MPPT Setup, TriStar DIP Switch, TriStar Setup, and TriStar MPPT Setup. These are accessible through the Tools menu. 5.5.
points to a file, read setpoints from the SSD, program to the SSD, edit displayed setpoints, or create a new setpoint profile. The next screen prompts the user for two sets of custom setpoints for Battery 1. DIP switch 1 will select between these two sets. Click Next when finished to customize settings for Battery 2. DIP switch 2 will select between Battery 2’s setpoint profiles.
NOTE: Disconnect power from the controller before changing any DIP switches; failure to do so will cause a fault. Please refer to the Help Topics in MSViewTM for more information. 5.5.5 TriStar Setup Wizard Custom settings can be programmed to the TriStar via MSViewTM. This wizard allows for step by step specification of these settings. After selecting the TriStar Setup Wizard, please read the warning and select OK if you accept the terms.
More information on individual controller settings are found in the Help Topics of the MSViewTM software. DIP Switch Positions for Custom Settings Device Settings SunSaver Duo Switch 4 ON (up) SunSaverMPPT Switches 4 ON (up) TriStar* Switches 4, 5 & 6 ON (up) TriStarMPPT* Switches 4, 5 & 6 ON (up) SureSine Switch 4 ON (up) Table 3. Morningstar Device Custom Settings DIP Switch Positions *MeterBus and MODBUSTM addresses will ALWAYS be updated, regardless of DIP switch settings. (i.e.
6.0 MSLoad 6.1 Overview Periodically, Morningstar will release firmware updates to their charge controllers. These updates will fix minor operational bugs, adjust operating parameters for better battery charging, or add additional features. Firmware updates are free and posted, as they become available, on the Morningstar website at www.morningstarcorp.com. The program used to update your controller’s firmware is called MSLoadTM.
! IMPORTANT: Some controllers (like the TSMPPT) contain two microprocessors. These units will need a firmware update for each processor. Such update files will be designated ‘A’ and ‘B’. The preceding steps assume the Morningstar unit has an on-board RS-232 connection. The next section describes how to update the firmware of a unit without an on-board DB-9 (RS-232) port. 6.
7.0 Website Hosting via HTTP 7.1 Overview Morningstar controllers with Ethernet connectivity will serve a basic collection of webpages enabling the user to: • view real-time system data • log historical system data • modify controller settings To access the unit’s served webpage from a computer on the network, open an internet browser (such as Internet Explorer or Firefox) and enter the factory default IP address of the product. (For example, the TriStar MPPT has a factory default IP address of 192.168.1.
8.0 E-mail Alerts / SNMP Traps 8.1 Overview Ethernet equipped Morningstar products provide alerts via E-mail, SMS (text message), or SNMP trap. Notifications can be enabled for the following conditions: • Self diagnostics fault condition (i.e. battery voltage sense failure) • Self diagnostics alarm condition (i.e. high-temp current limit) • User-defined event (i.e.
SMS alerts can be configured from the controller/inverter network settings webpage or MSViewTM. Proceed to enter the outgoing SMTP server address and username/password. Note: Most forms of webmail (Google, Yahoo, etc) are not supported as the outgoing SMTP server. This step will be the same as if you were configuring an e-mail alert. In the recipient’s e-mail address field, you will need to enter the cell phone @ the cell phone carrier’s SMS Gateway (i.e. 8885553333@vtext.com).
9.0 Data Logging 9.1 Overview Data logging is used to gather system relevant data and store it for later retrieval. Several Morningstar products will perform basic data logging to onboard memory. Please refer to specific product documentation for information on the internal logging performed by these units. For more advanced logging, (i.e.
9.4 Data Acquisition Service Some companies provide data collection services for your renewable energy system. All the interfacing, programming, and setup are done by the service provider. Usually, the service provider collects data and displays it on a secure website to be accessed at the customer’s convenience. Data can often be converted to a graphical format, making it easier to understand for customers without a technical background.
10.0 Network Security General Morningstar controllers/inverters do not contain any built-in security features or protections. The user is responsible for security through network configuration and settings. There will be no login or password required to communicate with the controller/inverter. If your system has internet access, use of a firewall is highly recommended to prevent unauthorized users from accessing the controller.
Figure 36. Digi TransPort Cellular Modem Family For wireless cellular connections, the Digi TransPort Cellular Modem famiily provides enhanced security features for enterprise-class applications. (Shown above.
11.0 Troubleshooting & Misc. Basic Serial Communication Problems If you are having problems communicating with a Morningstar product while using a serial to serial (or serial to RJ-11) connection: • Make sure the device is powered with a battery or power supply. The device cannot communicate without power. • Verify that the serial cable is not a Null Modem or crossover cable. • Verify that no other programs or managers are attempting to use the same serial port.
Power must be applied as follows: + Power must be asserted on the DTR and/or RTS pins - Power must be asserted on the RTS and/or RX pins Modifications can be made to your equipment (or RS-232 cable, but this is usually more difficult) so that the correct power is delivered to the Morningstar unit. Internally wiring several pins is usually all that is needed, but there is some equipment that does not provide negative (-) power at all, on any pin.
attenuation requirements, therefore, the following figures are simply a guideline as many factors will affect them. Remember: In general, the shorter the wiring, the less attenuation and/or timing problems will occur. Interface Standard Maximum Distance 30 meters 15 meters 1.2 kilometers 5 meters 100 meters RJ-11 MeterBus RS-232 RS-485 USB RJ-45 Ethernet Table 4. Standard Cable Interface Max. Distances Several devices can be used to increase these lengths.
RSC-1 Status LED Status LED Off Green Green / Red Flicker Orange Indication No bus power or reversed polarity Power OK, No data on network Data on network Reversed A & B data lines Notes Check bus power and polarity Wiring OK, Ready for data Network OK Check network wiring Table 7. RSC-1 Status LED Indicator States ------------ Ethernet Jack Status LEDs Condition Network Connection OK Network Activity Error Green LED ON ON OFF Yellow LED OFF Blinking ON Table 8.
1 2 3 4 5 6 7 8 9 MOXA MGate Serial Port Straight Through Serial Cable 1 [unused] (2) TX (3) RX (4) DTR (5) GND 6 [unused] (7) RTS 8 [unused] 9 [unused] Morningstar Serial Port Figure 38. MOXA MGate pin adjustment. EIA-485 Bridging Notes • Controllers with EIA-485 bridging capability will bridge all MODBUS TCPTM communications arriving from the Ethernet port to the EIA-485 network.
T-568B -------------------------Pin Color Pin Name ---------------------1 Orange Stripe Tx+ 2 Orange Tx3 Green Stripe Rx+ 4 Blue 5 Blue Stripe 6 Green Rx7 Brown Stripe 8 Brown The other end should have this pinout: T-568B -------------------------Pin Color Pin Name ---------------------1 Orange Tx2 Orange Stripe Tx+ 3 Green Rx4 Blue 5 Blue Stripe 6 Green Stripe Rx+ 7 Brown Stripe 8 Brown NOTE: This wiring modification will be nece
Appendix I - TSMPPT Networking I. Introduction Certain models of the TriStar MPPT family of charge controllers have Ethernet ports and web features. These models can be connected to your home network so that operating information can be displayed on any computer on the network. This Appendix covers the steps required to connect your ethernet-enabled TriStar MPPT controller to your home network.
Figure 1. Windows PC ipconfig network info In figure 1 above, the arrow points to the DHCP information. If your computer has DHCP enabled, then your network supports DHCP. Proceed to Step 1 in this section to connect your TriStar MPPT controller to your network. If DHCP is disabled, you will need to configure the TriStar MPPT with the correct network settings before proceeding. Follow the steps in Appendix A: Manual Network Configuration.
up to communicate. Before proceeding to the next step, allow 5 minutes for the controller to connect to the network and acquire its network settings. Step 2 Next, connect to the controller using a computer on the network. Microsoft PC 1. Open a web browser 2. In the internet address bar type the following: http://tsmpptXXXXXXXX/test.html where “XXXXXXXX” is the 8-digit serial number of the controller. The serial number can be found on the label on the side of the unit.
III. Configure Remote Access Configure remote access to allow communication with your TriStar MPPT from any computer or device on the internet. Use MSView or a web browser to view your solar system’s real-time operating information. NOTE: Before proceeding, make sure the TriStar MPPT is correctly configured and connected to your home/ business network per the directions in Section II.
b. c. d. e. Open the TriStar MPPT live view webpage Click the “Network” link at the top of the page Write down all the information in the Current Network Settings section Also note under the “Settings” section if “Obtain IP address from DHCP server” is selected. Step 2 - Login to the network Router a. Open a web browser on any computer on your local network b. Enter the IP of the “Default Gateway” listed in the TriStar MPPT network settings c.
provides a comprehensive list of routers and instructions for forwarding ports.
Figure 2. Dynamic DNS service Figure 2 above illustrates how DDNS works. Dynamic DNS servers are notified by a computer on Jack’s private network whenever the router IP changes. The address: JacksHouse.dyndns.org points to the DDNS servers which in turn forward the request to the latest IP address of Jack’s Private Network. Who provides this service and how much does it cost? We recommend using Dynamic DNS service provided by www.DynDNS.com. It’s free, reliable, and has a proven track record.
built-in EIA-485 interface. The TriStar MPPT 60 connects to a network router using the Ethernet port. All devices in the system are connected together on a EIA-485 bus. Incoming requests from the LAN or Internet that are addressed to devices on the network are bridged through the TriStar MPPT 60 onto the EIA-485 bus. For products such as the Relay Driver that have a serial port, an EIA-485 adapter (model:RSC-1) can be used to connect to the EIA-485 bus as shown in figure 3 below.
V. Additional Info Manual Network Configuration For networks that do not support DHCP, the TriStar MPPT must be configured manually. Follow these steps to manually configure the network settings for the TriStar MPPT. a. Open a web browser on any computer on your local network b. Enter the IP of the “Default Gateway” listed in the network settings information. Instructions for obtaining the network information are provided in the introductory notes in Section II. c.
Bridged Ethernet MODBUS requests to the EIA-485 network are Disabled. SNMP MIB file TSMPPT.mib can be downloaded from the HTTP Server’s root directory. A link is also provided on the Network settings page.
Appendix II - Advanced System Example 66 Appendix II - Advanced System Example
