Solar System Controller Installation and Operation Manual ..... Solar Battery Charging ..... Load Control .....
Table of Contents Important Safety Instructions.................................................................................................................. iii 1.0 TriStar Description ......................................................................................................................... 1.1 Versions and Ratings ......................................................................................................... 1.2 Operating Modes ...............................................
Table of Contents 6.0 7.0 continued Diversion Charge Control ......................................................................................................... 6.1 Diversion Charge Control ............................................................................................... 6.2 Diversion Current Ratings............................................................................................... 6.3 Standard Diversion Battery Charging Programs ...........................................
Battery Safety continued • 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 rings and jewelry when working with batteries. • Use insulated tools and avoid placing metal objects in the work area. • Carefully read the battery manuals before installing and connecting the controller. • Be very careful not to short circuit the cables connected to the battery.
1.0 TriStar Description The TriStar is a technically advanced solar system controller. There are three operating modes programmed into each TriStar. This manual describes solar battery charging, and specific load control or diversion charge control instructions are inserted where required. This manual will help you to become familiar with the TriStar’s features and capabilities. Some of these follow: • UL Listed (UL 1741) and cUL Listed (CSA-C22.2 No. 107.
Load & Lighting control When set for load control, the TriStar powers loads from the battery, and protects the battery from over-discharge with a current compensated LVD (low voltage load disconnect). Lighting control is a special function of Load control where the load is switched On and Off based on the solar array voltage. Diversion charge control In diversion mode, the TriStar will manage battery charging by diverting energy from the battery to a dedicated diversion load.
1.5 Safety and Regulatory Information 1.6 Three optional components can be added to the standard TriStar controller at any time. The TriStar controller is intended for installation by a qualified technician according to electrical rules of each country in which the product will be installed. 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.
2.0 TriStar Installation The installation instructions describe solar battery charging. Specific instructions for the load control and diversion modes are provided as notes. General Information 4. The mounting location is important to the performance and operating life of the controller. The environment must be dry and protected as noted below. The controller may be installed in a ventilated enclosure with sealed batteries, but never in a sealed battery enclosure or with vented batteries. 5. 6.
Step 5. 6. 7. Lighting Control ( c o n t i n u e d ) Connect the battery power wires to the TriStar. Then connect the load wires. Connect a computer to the TriStar if making adjustments with PC software. Replace the cover. Steps #3, #4, and #5 are required for all installations. Steps #6 is optional. See Section 2.3, Step 5 for more information about array voltage measurement. Steps #4, #5, and #7 are optional. 2.
flow for cooling. remaining two screws to fasten the controller to the wall. Before starting the installation, place the TriStar on the wall where it will be mounted and determine where the wires will enter the controller (bottom, side, back). Remove the appropriate knockouts before mounting the controller. The knockouts are sized for 1 inch and 1.25 inch conduit. Provide for strain relief for the bottom knockouts if conduit will not be used.
REMARQUE : Les commutateurs DIP ne doivent être remplacés que si le contrôleur est hors tension. Mettez tous les interrupteurs sur arrêt et mettez le contrôleur hors tension avant de changer un commutateur DIP. Une panne sera indiquée en cas de changement d’un commutateur alors que le contrôleur est sous tension. ON ON DIP Auto Select PRUDENCE : Le TriStar est expédié avec tous les interrupteurs en position « ARRÊT ». La position de chaque interrupteur doit être confirmée pendant l’installation.
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 REMARQUE : Confirmez les réglages de tous les commutateurs dip avant de passer aux étapes suivantes d’installation.
voltage sense input avoids the large voltage drops that can occur in the battery power conductors. The voltage sense connection allows the controller to measure the actual battery voltage under all conditions. NOTE: Lighting mode uses the battery sense connection to measure the voltage of the system array to determine day and night condition. Do not use the sense connection to measure battery voltage in lighting mode.
Minimum Overcurrent Device Ratings To comply with NEC requirements, overcurrent protection must be provided externally in the system. The NEC requires that each overcurrent device is never operated at more than 80% of its rating.
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. 3.1 Torque each of the four power terminals to 5.65 Nm (50 in-lbs). Power-Up • Confirm that the solar (or load) and battery polarities are correct. • Turn the battery disconnect on first. Observe the LED’s to confirm a successful start-up.
3.3 Valuable information can be provided by the three LED’s 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.
down to 50A, which is equivalent to the heating from a normal 60A solar input. LOAD & LIGHTING CONTROL Load overload: (R/Y-G sequencing) If the load current exceeds 100% of the controller’s rating, the controller will disconnect the load. The greater the overload, the faster the controller will disconnect. A small overload could take a few minutes to disconnect.
RTS, the controller may not detect that the RTS is connected, and the LED’s 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 Solar Battery Charging 4.1 Battery voltage sense failure: (R/Y-G/Y) If a fault in the battery sense connection (such as a short circuit, open circuit, loose terminal) occurs after the battery sense has been working, the LED’s will indicate a failure.
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 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. Section 4.
Float Float is less affected by temperature changes, but it may also undercharge or gas too much depending on how much the temperature changes. 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.
cell. The overall battery voltage is 28.8V, but the individual cells are higher or lower due to cell drift. Equalization cycles help to bring all the cells to the same voltage. 14 days). When an equalization begins (auto or manual), the battery charging voltage increases up to the equalization voltage (Veq). The battery will remain at Veq for the time specified in the selected charging program (see table in 4.2). Mix the electrolyte.
can be used to adjust these values. Refer to Section 9.0 for more information 5.0 Load & Lighting Control about charging sealed batteries. 4.5 This section describes the user selectable load control settings (5.1) and the low voltage load disconnect (LVD) warning indications (5.2). Load information and general cautions are provided in the remaining sections.
TS-45 TS-60 12V –15 mV per amp –10 mV per amp 24V –30 mV per amp –20 mV per amp 48V –60 mV per amp –40 mV per amp As an example, consider a 24V system using a TriStar-60 with a 30 amp load. The LVD will be reduced by 0.02V (per the table above) times 30 amps. This equals –0.6V. A DIP-switch selected LVD of 23.4V would be reduced to 22.8V in this example. setpoint. Lower LVD voltage settings may result in the battery discharging 70% or 80% of its capacity.
6.0 Diversion Charge Control 5.5.3 The TriStar’s third mode of operation is diversion load battery charge control. As the battery becomes fully charged, the TriStar will divert excess current from the battery to a dedicated diversion load. This diversion load must be large enough to absorb all the excess energy, but not too large to cause a controller overload condition.
9.0 The table below summarizes the major parameters of the standard diversion battery charging algorithms. Note that all the voltages are for 12V systems (24V = 2X, 48V = 4X). 6.4 All values are 25ºC (77ºF). A. DIP Switches (4-5-6) PWM Absorp. Voltage off-off-off off-off-on off-on-off off-on-on on-off-off on-off-on on-on-off on-on-on 13.8 14.0 14.2 14.4 14.6 14.8 15.0 B. C. Float Voltage Time Until Float (hours) 13.6 13.6 13.6 13.6 13.7 13.7 13.7 Custom 4 4 4 4 4 4 4 D. E. F. G.
Nominal Voltage 48V 24V 12V draw. This peak load current must not exceed the TriStar’s rating. 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. Load Power Ratings The power rating of the diversion load will depend on the voltage of the battery being charged.
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 setpoints and operating parameters to be easily adjusted.
7.3 Changing Setpoints 8.0 Self-Testing / Diagnostics 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.
• Battery charging requires temperature compensation (connect a remote temperature sensor) • Load is too large and is discharging the battery 9.0 Battery Information The standard battery charging programs in the TriStar controller, as described in Section 4.
cell voltages. There are also combinations of plate chemistries that offer beneficial tradeoffs. For example, low antimony and selenium plates can offer fairly good cycling performance, long life, and reduced watering needs. Other Sealed Batteries: Automotive and “maintenance-free” batteries are also sealed. However, these are not discussed here because they have very poor lifetimes in solar cycling applications.
10.0 Warranty 11.0 Technical Specifications LIMITED WARRANTY The TriStar-45 and TriStar-60 controllers are 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 fault with the controller.
MECHANICAL • Dimensions (mm/inch) • Weight (kg/lb) • Power terminals: largest wire smallest wire • Terminal wire slot • Knockout sizes • Torque terminals • RTS / Sense terminals: wire sizes torque • • • • ENVIRONMENTAL Ambient temperature Storage temperature Humidity Enclosure Appendix 1 — Load & Lighting Control DIP Switch Settings H: 260.4 mm / 10.25 inch W: 127.0 mm / 5.0 inch D: 71.0 mm / 2.8 inch 1.6 kg / 3.5 lb compression connector lug 35 mm2 / 2 AWG 2.5 mm2 / 14 AWG 8.2 mm / 0.324 in wide 9.
4, 5, 6 7 8 Lowest LVD = 11.1V Not used (selects diversion mode) Not used DIP Switches Number 4,5,6 - Load Control Algorithm: For normal Load Control Mode, set the DIP switches 4,5,&6 according to the table below. For Lighting Control, see the table and Figure 2.4 on the next page. To configure your TriStar for the Load Control you require, follow the DIP switch adjustments described below. To change a switch from OFF to ON, slide the switch up toward the top of the controller.
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.
position, the following functions are present: Appendix 2 - Diversion Charge Control DIP Switch Settings Switch 1 2, 3 4, 5, 6 7 8 The Diversion Charge Control functions that can be adjusted with the DIP switches follow: ON ON OFF 1 2 3 DIP 5 6 8 Function Must be “ON” (load control) Auto voltage select Lowest battery charging voltage Must turn “ON” to select Diversion Manual Equalization To configure your TriStar for the diversion battery charging and control you require, follow the DIP switch ad
DIP Switches Number 4,5,6 - Diversion Charge Control: Battery Type PWM Switch 4 Switch 5 1 13.8 Off Off 2 14.0 Off Off 3 14.2 Off On 4 14.4 Off On 5 14.6 On Off 6 14.8 On Off 7 15.0 On On 8 Custom On On ON ON ON DIP DIV 13.8V ON ON DIP 1 2 3 4 5 6 7 8 OFF Figure 2.3 - Step 3 DIP Switch # 7 In the Diversion Charge Control mode, DIP switch #7 must be in the ON position. DIP DIV 14.
Appendix 3 - LED Indications 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.
66 APPENDICES
