Product Manual

18
TRISTAR INSTALLATION
19
MORNINGSTAR CORPORATION
2.02.0
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.
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. The minimum overcurrent
device ratings for TriStar controllers are as follows:
• TriStar-45 60 amps
• TriStar-60 75 amps
• Voltage rating 125 Vdc
• UL Listed for dc circuits
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
The minimum size of the copper grounding wire:
• TS-45 6 mm
2
(10 AWG)
• TS-60 10 mm
2
(8 AWG)
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 2.3 - 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