Installation Guide
55TriStar MPPT 600V Operator’s Manual
54
Operation
4.5 Protections, Faults & Alarms
The TriStar MPPT 600V protections and automatic recovery are important features that ensure
the safe operation of the system. Additionally, the TriStar MPPT 600V features real-time self
diagnostics that report Fault and Alarm conditions as they occur.
Faults are events or conditions that require the TriStar MPPT 600V to cease operation. A Fault
usually occurs when a limit such as voltage, current, or temperature has been surpassed. Fault
conditions are indicated with unique LED sequences and are also displayed on a TriStar Meter,
and in MSView software.
Alarms are events or conditions that may require the TriStar MPPT 600V to modify operation.
Alarms are commonly used to alert the user that the controller is nearing a specic voltage,
current, or temperature limit. Alarm conditions are only displayed on a TriStar Meter, and in
MSView software.
Some basic fault and alarm conditions are listed below.
Protections
Solar Overload
The TriStar MPPT 600V will limit battery current to the Maximum Battery Current rating. See
Figure 9-1 - Battery Current vs. Array Voltage de-rating graph - in Section 9.0. An over-sized
power source will not operate at peak power. The power source wattage should be less than the
TriStar MPPT 600V Nominal Maximum Input Power rating for optimal performance.
Solar High Input Voltage
As the array open-circuit voltage approaches the 600 Volt maximum input voltage limit, solar
input current will be limited.
High Temperature
The TriStar MPPT 600V will limit the solar input current if the heatsink temperature exceeds safe
limits. Solar charge current will be tapered back (to 0 amps if needed) to reduce the heatsink
temperature.
Faults
Remote Temperature Sensor Failure (R+Y / G+Y)
If a fault in the RTS (such as a short circuit, open-circuit, loose terminal) occurs after the RTS has
been working, the LEDs will indicate a failure. However, if the controller is restarted with a failed
RTS, the controller may not detect that the RTS is connected, and the LEDs will not indicate a
problem. A TriStar meter or the PC software can be used to determine if an RTS is detected and
working properly.
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 LEDs will indicate a failure. If the control-
ler is restarted with the failure still present, the controller may not detect that the battery sense is
connected and the LEDs will not indicate a fault. A TriStar meter or the PC software can be used
to determine if the battery sense is working properly.
Settings (DIP) Switch Changed (R / Y / G sequencing)
If a settings switch is changed while there is power to the controller, the LEDs will begin
sequencing and the solar input will be disconnected. The controller must be restarted to clear
the fault and begin operation with the new settings.
Battery Low Voltage Disconnect (R / Y / G sequencing)
If the battery voltage is too low, the unit will stop operation. The LED indication alerts the user
that the battery is below a safe voltage. When battery voltage rises to the Battery Low Voltage
Reconnect threshold, the fault will automatically clear.
Battery High Voltage Disconnect (G / R sequencing)
This fault is occurs when battery voltage is above normal operating limits. The controller
will disconnect the solar input, and indicate a High Voltage Disconnect fault. This fault is
commonly caused by other charging sources in the system charging the battery above the
TriStar MPPT 600V regulation voltage. When the battery voltage returns to normal levels, the
fault will automatically clear.
Custom Settings Edit (R / Y / G sequencing)
A value has been modied in custom settings memory. The controller will stop charging and
indicate a fault condition. After all settings have been modied, the controller must be reset by
removing and then restoring power to the controller. The new programmed settings will be used
after the power reset.
Firmware Update Failure (start-up interrupted - stops on Y)
The rmware 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 control-
ler will not complete start up or begin charging. Retry the rmware update. The rmware must be
successfully loaded before the controller will start up. Note: the second indication of rmware
update failure is that the other processor is not responding.
Solar Over-Current (Y + R / G)
While rare, if battery charging current exceeds approximately 130% of the controller’s output
current rating, this fault can occur. The fault is generally related to fast, large battery voltage
transients (connecting a very heavy or capacitive load like an inverter) that are faster than the
controller can regulate and it shuts off to protect the circuitry. The controller will automatically
re-start in 10 seconds.