TRISTAR MPPT TM Solar Charging System Controller Installation, Operation and Maintenance Manual For the most recent manual revisions, see the version at: www.morningstarcorp.com Solar Battery Charger With TrakStar TM Maximum Power Point Tracking Technology www.morningstarcorp.
Dimensions in Inches [Millimeters] TABLE OF CONTENTS 1.0 Important Safety Instructions 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 10 10 10 11 13 14 16 3.1 General Information 16 3.2 Controller Installation 18 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.
1.0 Important Safety Instructions SAVE THESE INSTRUCTIONS. This manual contains important safety, installation and operating instructions for the TriStar MPPT 150V 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.
• This charge controller is to be connected to DC circuits only. These DC connections are identified by the symbol below: • Ce contrôleur de charge ne doit être connecté qu’à des circuits en courant continu. Ces connexions CC sont identifiées par le symbole ci-dessous: Direct Current Symbol The TriStar MPPT 150V controller must be installed by a qualified technician in accordance with the electrical regulations of the country where the product is installed.
• Servicing of batteries should be performed, or supervised, by personnel knowledgeable about batteries, and the proper safety precautions. • Be very careful when working with large lead-acid batteries. Wear eye protection and have fresh water available in case there is contact with the battery acid. • Remove watches, rings, jewelry and other metal objects before working with batteries.
2.0 Getting Started 2.3 Features The features of the TriStar MPPT 150V are shown in Figure 2-1 below. An explanation of each feature is provided. 2.1 Overview 1 Thank you for selecting the TriStar MPPT 150V solar charge controller with TrakStarTM MPPT Technology. The TriStar MPPT 150V (TS-MPPT) is an advanced maximum power point tracking solar battery charger.
2.4 Regulatory Information 1 - Heatsink Aluminum heatsink to dissipate controller heat NOTE: This section contains important information for safety and regulatory requirements.
2.5 Optional Accessories Ethernet Meterbus Converter (EMC-1) 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 / TSRM-2) The EMC-1 acts as an Ethernet gateway that serves MODBUS IP, local Web pages, and Web Monitoring Services. Note that the Web Monitoring Service is not currently available.
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 150V in a sealed enclosure. The controller may be mounted in an enclosure with sealed batteries, but never with vented/flooded batteries.
3.2 Controller Installation Step 2 - Remove the Knock-Outs 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 150V power connections. ! PRUDENCE : Risque de décharge électrique Déconnectez toutes les sources d’alimentation du contrôleur avant d’enlever le couvercle du boîtier de câblage.
3. Place a mark on the mounting surface at the top of the keyhole. Step 3 - Mount to a Vertical Surface 4. Remove the controller and drill a 3/32” (2.5 mm) hole at the drill mark. ! CAUTION: Risk of Burns Install the TriStar MPPT 150V in a location that prevents casual contact. The TriStar MPPT 150V heatsink can become very hot during operation. 5. Insert a #10 screw (included) into the top pilot hole. Do not tighten the screw completely.
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.
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 battery (+) terminal lug and the LED stack (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 7 - Battery Voltage Sense The voltage at the battery connection on the TriStar MPPT 150V 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 150V to measure the battery terminal voltage precisely with small gauge wires that carry very little current, and thus have no voltage drop.
Step 9 - Power Connections 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: To comply with the NEC, the TriStar MPPT 150V must be installed using wiring methods in accordance with the latest edition of the National Electric Code, NFPA 70. NOTE: The RS-232 and EIA-485 ports share hardware. Both ports cannot be used simultaneously.
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. The NEC requires solar and battery fuses or DC breakers to be installed in the system. These protection devices are external to the TriStar MPPT 150V controller, and must be a maximum of 45 amps for the TS-MPPT-30, 70 amps for the TS-MPPT 45, and 90 amps for the TS-MPPT-60/M.
WARNING: Risk of Damage Be very certain that the solar connection is made with correct polarity. Turn on the solar array breaker/disconnect and measure the voltage on the open wires BEFORE connecting to the TriStar MPPT 150V. Disconnect the solar breaker/ disconnect before wiring to the controller. AVERTISSEMENT : Risque d’endommagement Assurez-vous que la connexion solaire est effectuée avec la polarité correcte.
The TriStar MPPT 150V 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 150V as described in this section. 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.
4.2 Battery Charging Information Float Stage 4-Stage Charging VOLTAGE The TriStar MPPT 150V has a 4-stage battery charging algorithm for rapid, efficient, and safe battery charging. Figure 4-2 shows the sequence of the stages. Once in Float stage, loads can continue to draw power from the battery. In the event that the system load(s) exceed the solar charge current, the controller will no longer be able to maintain the battery at the Float set-point.
Certain battery types benefit from a periodic boost charge to stir the electrolyte, level the cell voltages, and complete the chemical reactions. Equalize charging raises the battery voltage above the standard absorption voltage so that the electrolyte gases. The green SOC LED will blink 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 TriStar MPPT 150V provides seven (7) standard battery charging settings that are selectable with the settings DIP switches (see Figure 4.1 above). These standard charging settings are suitable for lead-acid batteries ranging from sealed (gel, AGM, maintenance-free) to Flooded and L-16 cells. In addition, an 8th charging setting provides for custom set-points using MSViewTM PC software. Shared Settings Value Units 12.50 Volts Absorption Time + 30 minutes 60 minutes 12.
the battery. The controller will begin 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 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 0.3V drop between the controller and battery.
REMARQUE : Avec plusieurs contrôleurs TriStar MPPT 150V sur un réseau MeterBusTM, initialisez une compensation de batteries à l’aide de l’outil de mesure TriStar afin de synchroniser tous les contrôleurs. Note that if two or more TriStar MPPT 150V controllers are charging in parallel, each controller may attempt to equalize on a different day. Systems with multiple controllers should only equalize manually to ensure synchronization between controllers. 4.
4.5 Protections, Faults & Alarms The TriStar MPPT 150V protections and automatic recovery are important features that ensure the safe operation of the system. Additionally, the TriStar MPPT 150V features real-time self diagnostics that report Fault and Alarm conditions as they occur. Faults are events or conditions that require the TriStar MPPT 150V to cease operation. A Fault usually occurs when a limit such as voltage, current, or temperature has been surpassed.
Firmware Update Failure The firmware update was not successfully programmed. The controller will not indicate the full power-up LED sequence of G - Y - R when power to the controller is reset. Instead, the controller will display green and then stop on yellow. The yellow LED will continue to be lit and the controller will not complete start up or begin charging. Retry the firmware update. The firmware must be successfully loaded before the controller will start up.
Schedule 2 weeks after installation 3 months after installation Maintenance Items Re-tighten power terminal connections to specified torque values. Re-tighten power terminal connections to specified torque values. 5.0 Networking and Communication 5.1 Introduction The TriStar MPPT 150V provides several communication options.
5.2 Morningstar MeterBusTM 5.3 Serial RS-232 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 150V 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.
5.4 EIA-485 (formerly RS-485) 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 150V 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.
5.5 Ethernet Factory Default Network Settings NOTE: Ethernet is only available on the TS-MPPT-60/M 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.
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 150V self diagnostics fault condition • TriStar MPPT 150V 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 150V wizard. View Logged Data The TriStar MPPT 150V logs up to 200 days* of daily data.
7.0 Warranty and Claim Procedure NOTE: For more in-depth testing and diagnosis, download the TriStar MPPT 150V Testing Document from the Support section on our website: www.morningstarcorp.
8.0 Specifications WARRANTY CLAIM PROCEDURE Electrical TS-MPPT-30 1. Before proceeding, please refer to product manual, including troubleshooting section.
Battery Charging Status LEDs De-ratings Battery Charging Status 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 < 12.0 Volts Mechanical (H) 291 mm / 11.44” (W) 130 mm / 5.12” (D) 142 mm / 5.58” 4.
Efficiency TriStar MPPT 48 Volt Efficiency TriStar MPPT 12 Volt Efficiency 100 98 97 13 Vmp 96 16.5 Vmp 97 efficiency (%) 66 Vmp 94 93 66 Vmp 83 Vmp 98 Vmp 98 95 efficiency (%) 52 Vmp 99 98 Vmp 92 96 95 94 93 91 92 90 91 89 90 88 0 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 output power (Watts) 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.
2% Voltage Drop Charts for 75°C Stranded Copper Wire 2% Voltage Drop Charts for 75°C Solid Copper Wire 1-Way Wire Distance (feet), 12 Volt System 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 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 2/0 ** 27.8 30.3 33.4 37.1 41.
2% Voltage Drop Charts for 90°C Stranded Copper Wire 2% Voltage Drop Charts for 90°C Solid Copper Wire 1-Way Wire Distance (feet), 12 Volt System 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 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 2/0 ** 27.8 30.3 33.4 37.1 41.
9.0 Certifications Certifi ® TUVRheinland CERTIFIED THIS PAGE IS LEFT BLANK INTENTIONALLY • • • • Complies with UL 1741, 62109 and CSA-C22.2 No. 107.
