TRISTAR MPPT 600V TM Solar System Controller Installation and Operation Manual TrakStar TM Solar Battery Charger With Maximum Power Point Tracking Technology 8 Pheasant Run Newtown, PA 18940 USA email: info@morningstarcorp.com www.morningstarcorp.
Dimensions in Inches [Millimeters]
Contents 1.0 Important Safety Instructions 2.0 Getting Started 2.1 Overview 2.2 Regulatory Information 2.3 Versions and Ratings 2.4 Features 2.5 Optional Accessories 3.0 Installation 3.1 General Information 3.2 Wiring Zones 3.3 Conduit Knock-outs and Wiring Routing 3.4 Controller Installation 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 5.0 Networking and Communication 5.1 Introduction 5.
1.0 Important Safety Instructions SAVE THESE INSTRUCTIONS This manual contains important safety, installation and operating instructions for the TriStar MPPT 600V 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.
Installation Safety Precautions WARNING: This unit is not provided with a GFDI device. This charge controller must be used with an external GFDI device as required by the Article 690 of the National Electrical Code for the installation location. • Mount the TriStar MPPT 600V indoors. Prevent exposure to the elements and do not allow water to enter the controller. • Install the TriStar MPPT 600V in a location that prevents casual contact. The TriStar MPPT 600V heatsink can become very hot during operation.
Précautions de Sécurité D’installation AVERTISSEMENT: L’appareil n’est pas fourni avec un dispositif GFDI. Ce contrôleur de charge doit être utilisé avec un dispositif GFDI externe tel que requis par l’Article 690 du Code électrique national de l’emplacement de l’installation. • Montez le TriStar MPPT HV à l’intérieur. Empêchez l’exposition aux éléments et la pénétration d’eau dans le contrôleur. • Utilisez des outils isolés pour travailler avec les batteries.
WARNING: A battery can present a risk of electrical shock or burn from large amounts of short circuit current, fire, or explosion from vented gases. Observe proper precautions. CAUTION: When replacing batteries, use properly specified sizes, types, and ratings based on application and system design. CAUTION: Proper disposal of batteries is required. Refer to local regulations or codes for requirements.
2.0 Getting Started 2.1 Overview Thank you for selecting the TriStar MPPT 600V solar charge controller with TrakStarTM MPPT Technology. The TriStar MPPT 600V (TS-MPPT-60-600V) is an advanced maximum power point tracking solar battery charger. The controller features a smart tracking algorithm that finds and maintains operation at the solar array peak power point, maximizing energy harvest.
NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communication.
2.4 Features The features of the TS-MPPT-60-600V-48 model are shown in Figure 2-1 below. An explanation of each feature is provided. 1 17 16 15 2 14 3 13 4 12 5 6 11 7 10 9 Figure 2-1.
1 - Heatsink Aluminum heatsink to dissipate controller heat (the TriStar MPPT 600V is 100% passively cooled for reliability) 2 - LED Indicators Three state of charge (SOC) LED indicators show charging status and controller faults 3 - Settings Switches Eight (8) settings switches to configure operation of the TriStar MPPT 600V 4 - Battery Positive Terminal (red) Power connection for Battery (+) 5 - MeterBusTM Port RJ-11 socket for Morningstar MeterBusTM network connections 6 - Ethernet Port RJ-45 sock
The features of the TS-MPPT-60-600V-48-DB model are shown in Figure 2-2 below. An explanation of each feature is provided.
1 - Heatsink Aluminum heatsink to dissipate controller heat (the TriStar MPPT 600V is 100% passively cooled for reliability) 2 - Battery Negative Power Terminal Power connection for (-) battery cable termination 3 - Battery Positive Power Terminal (red) Power connection for (+) battery cable termination 4 - Settings Switches Eight (8) settings switches to configure operation of the TriStar MPPT 600V-DB 5 - MeterBusTM Port RJ-11 socket for Morningstar MeterBusTM network connections 6 - Ethernet Port
2.5 Optional Accessories The accessories described below are available for purchase separately from your authorized Morningstar dealer. Please see the individual product manuals for installation and operation details. Ground Fault Protection Device (GFPD-600V) The GFPD detects solar array ground faults and disconnects the solar circuit as required by the U.S. National Electrical Code.
Relay Driver (RD-1) The Relay DriverTM accessory enables the TriStar MPPT 600V to control external devices. Four (4) relay control ports can be configured (in various combinations) to perform the following tasks: • • • • • generator control (2-, 3-, and 4-wire configurations) dry contacts for alarms and other signals advanced load control vent fan control DIN rail compatible or surface mount For more information on the Relay Driver, visit our website at www.morningstarcorp.
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 600V in a sealed enclosure. The controller may be mounted in an enclosure with sealed batteries, but never with vented/flooded batteries.
Recommended Tools: • • • • Wire strippers Wire cutters #2 & #0 Phillips screwdriver slotted screwdrivers • • • • Pliers Drill3/32” (2.5 mm) drill bit Level hack saw (cutting conduit) 3.2 Wiring Zones The 600V solar circuits must be separated from the low voltage battery circuits and communication wiring within the wiring box. Figure 3-1 below shows the high voltage and low voltage zones (shaded) within the wiring box.
3.3 Conduit Knock-Outs and Wire Routing Knock-outs are provided for routing cables through conduit or wire glands. Table 3-1 details the knockout sizes and quantity provided on the TriStar MPPT 600V wiring box. Knockout placement dimensions are on the inside front cover. Figures 3-2 to 3-5 show knock-out types. The TriStar MPPT 600V wiring box provides continuous and separate paths for high voltage (solar) and low voltage (battery & COM) wiring routing.
7 10 8 9 Figure 3-4. Knock-outs, bottom view 12 11 Figure 3-5. Knock-outs, back view Item Quantity Trade Size Hole Dimension Circuit(s) Pass-Through? 1 2 (Concentric) 1” & 3/4” 1.36“ (34.5 mm) / 1.09” (27.8 mm) Solar (high voltage) YES 2 2 (Concentric) 1-1/4 “ & 1 “ 1.72” (43.7 mm) / 1.36“ (34.5 mm) Battery (low voltage) YES 3 4 Fits select MC-style Solar connectors ** 18 mm Solar (high voltage) NO 4 3 1/2” or M20 7/8” (22.
Communication Wiring Battery Wiring Solar Wiring Figure 3-6. Wiring pass-through paths between multiple controllers 3.4 Controller Installation (TS-MPPT-60-600V-48 and TS-MPPT-60-600V-48-DB) 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 600V power connections.
Figure 3-7. Remove the wiring box cover. Step 2 - Remove the Wiring Divider (TS-MPPT-60-600-V48 and TS-MPPT-60600V-48-DB) and Solar Terminal Bridge (TS-MPPT-60-600V-48 ONLY) The wiring divider separates the solar high voltage wiring from the low voltage battery and communication circuits. See Figure 3-8 . The divider is secured with only one screw. 1. Use a #2 Philips screw driver to remove the screw. 2. Lift and tilt the divider towards the bottom of the unit as shown in Figure 3-8. 3.
3 1 2 Figure 3-8. Remove the Wiring Divider. The Solar Terminal Bridge provides a safe path between the Solar power terminals and the 600V high voltage wiring area. The bridge is removable to allow access to the conduit knock-outs below the bridge. To remove the bridge, gently pull the bridge straight out of the wiring box as shown in figure 3-9. Figure 3-9. Remove the Solar Terminal Bridge.
Step 3 - Remove the Knock-Outs Plan the routing of each conductor that will connect to the TriStar MPPT 600V before removing any knock-outs. The 1/2” (M20) knock-outs are ideal for routing network cables, which must be placed in separate conduit. Use a flat head screwdriver to remove the necessary knock-outs. A hammer may also be required to apply extra force. Refer to Section 3.2 for detailed knockout information.
and below and at least 1” (25 mm) between the controller and adjacent walls for proper air flow as shown in figure 3-11 below. WARM AIR AT LEAST 1” (25 mm) COOL AIR AT LEAST 6” (150 mm) AT LEAST 6” (150 mm) Figure 3-11. Required mounting clearance for air flow. 3. Place a mark on the mounting surface at the top of the keyhole. 4. Remove the controller and drill a 3/32” (2.5 mm) hole at the drill mark. 5. Insert a #10 screw (included) into the top pilot hole. Do not tighten the screw completely.
Step 5 - Network Connections Network connections allow the TriStar MPPT 600V to communicate with other controllers or computers. A network can be as simple as one controller and one PC, or as complex as dozens of controllers monitored via the internet. Review section 5.0 for more information about networking and the connection(s) required for your system. WARNING: Shock Hazard Never route network cables in the same conduit as the power conductors.
Figure 3-13. Removing the EIA-485 socket connector 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: The RS-232 and EIA-485 ports share hardware. Both ports cannot be used simultaneously. REMARQUE : Les ports RS-232 et EIA-485 partagent le matériel. Ils ne peuvent pas être utilisés simultanément.
Step 6 - Power Connections NOTE: To comply with the NEC, the TriStar MPPT 600V must be installed using wiring methods in accordance with the latest edition of the National Electric Code, NFPA 70. REMARQUE : Pour la conformité CNE, le TriStar MPPT doit être installé selon des méthodes de câblage conformes à la dernière édition du Code électrique national, NFPA 70. Wire Size The four large power terminals are sized for 14 - 2 AWG (2.5 - 35 mm2) wire.
Over-Current Protection and 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. AVERTISSEMENT : Risque de décharge électrique Les fusibles, coupe-circuits et interrupteurs ne doivent jamais ouvrir les conducteurs du système mis à la terre. Seuls les dispositifs GFDI sont autorisés à déconnecter les conducteurs reliés mis à la terre.
SOLAR NEG. (-) SOLAR POS. (+) BATTERY POS. (+) BATTERY NEG. (-) Figure 3-14. Power Terminal Locations Connect the four (4) power conductors shown in figure 3-14 as described in the following steps: 1. Confirm that the system input and output disconnect switches are both turned off before connecting the power wires to the controller. 2. Pull PV and battery wires into the standard wiring box.
WARNING: Risk of Damage Be very certain that the battery connection is made with correct polarity. Turn on the battery breaker/disconnect and measure the voltage on the open battery wires BEFORE connecting to the TriStar MPPT 600V. Disconnect the battery breaker/disconnect before wiring to the controller. AVERTISSEMENT : Risque d’endommagement Assurez-vous que la connexion a la batterie est effectuée avec la polarité correcte.
PV TERMINAL LUGS 1 PV SWITCH (-) (+) BATTERY TERMINAL LUGS (-) (+) BATTERY DISCONNECT BREAKER Runs Below (+) Terminal Block (+) Block C+ (-) Block C- (+) Block C+ C- FROM ARRAY (-) Block TO BATTERY (-) (+) High-Low Voltage Barrier Not Shown Figure 3-15. Power Terminal Locations Connect the four (4) power conductors shown in figure 3-15 as described in the following steps: 1.
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 600V. 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.
Step 7 - 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 pushbutton and the LEDs (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.
wires may be pulled through conduit with the power conductors. Tighten the connector screws to 5 in-lb (0.56 Nm) of torque. The maximum length allowed for each battery voltage sense wire is 98 ft (30 m). Be careful to connect the battery positive (+) terminal to the voltage sense positive (+) terminal. No damage will occur if the polarity is reversed, but the controller cannot read a reversed sense voltage. Connecting the voltage sense wires to the RTS terminal will cause an alarm.
All settings are for 48 volt nominal systems. Descriptions of battery type and stages are provided below. See section 4.2 for full details. Battery Type - The most common battery type associated with the specified charging settings. Absorption Stage - This stage limits input current so that the Absorption voltage is maintained. As the battery becomes more charged, the charging current continues to taper down until the battery is fully charged.
! CAUTION: Risk of Tampering The Ethernet Security settings switch does not block write commands to devices bridged via EIA485. REMARQUE : Le réglage des paramètres de réseau et des points de consignes personnalisés est toujours activé par les connexions RS-232 et EIA-485. Le contacteur de sécurité Ethernet n’active/ désactive que la configuration à distance par TCP/IP.
AVERTISSEMENT : Risque d’incendie NE LIEZ PAS le côté négatif du système à la mise à la terre au niveau du contrôleur. Selon les exigences du CNE, le côté négatif du système doit être mis à la terre par un GFPD à un seul point. Step 11 - Power-Up (TS-MPPT-60-600V-48 and TS-MPPT-60-600V-48-DB) WARNING: Risk of Damage Connecting the solar array to the battery terminal will permanently damage the TriStar MPPT 600V.
4.0 Operation The TriStar MPPT 600V 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 600V as described in this section. 4.1 TrakStarTM MPPT Technology The TriStar MPPT 600V utilizes Morningstar’s TrakStarTM Maximum Power Point Tracking (MPPT) technology to extract maximum power from high voltage solar arrays commonly used in grid-tie applications.
4.2 Battery Charging Information 4-Stage Charging VOLTAGE The TriStar MPPT 600V has a 4-stage battery charging algorithm for rapid, efficient, and safe battery charging. Figure 4-0 shows the sequence of the stages. EQUALIZE NIGHT BULK CHARGE ABSORPTION FLOAT NIGHT TIME Figure 4-0. TriStar MPPT Charging Algorithm Bulk Charge Stage During Bulk charging, the battery is not at 100% state of charge and battery voltage has not yet charged to the Absorption voltage set-point.
Float Stage After the battery is fully charged in the Absorption stage, the TriStar MPPT 600V reduces the battery voltage to the Float voltage set-point. When the battery is fully recharged, there can be no more chemical reactions and all the charging current is turned into heat and gassing. The float stage provides a very low rate of maintenance charging while reducing the heating and gassing of a fully charged battery. The purpose of float is to protect the battery from long-term overcharge.
The duration of the equalize charge is determined by the selected battery type. See table 4-1 in this section for more details. The Equalization Time is defined as time spent at the equalize set-point. If there is insufficient charge current to reach the equalization voltage, the equalization will terminate after an additional 60 minutes to avoid over gassing or heating the battery.
After the equalization is finished, add distilled water to each cell to replace gassing losses. Check that the battery plates are covered. Equalize a Sealed Battery? The Battery Charging Settings table (see table 4-1 in this section) shows one sealed battery setting with an Equalization cycle. This is only a 0.4 Volt boost cycle to level individual cells. This is not an equalization, and will not vent gas from sealed batteries that require up to 57.60 V charging (48 V battery).
Battery Charging Settings The details of the TriStar MPPT 600V battery charging settings are shown in tables 4-1 and 4-2 below. All voltage settings listed are for nominal 48 Volt battery banks. Settings Switches 4-5-6 Battery Type Absorp. Stage (Volts) Float Stage (Volts) Equalize Stage (Volts) Absorp. Equalize Time Time (Minutes) (Minutes) Equalize Interval (Days) off-off-off 1 - Gel 56.00 54.80 off-off-on 2 - Sealed* 56.60 54.80 57.60 150 60 28 off-on-off 3 - Sealed* 57.20 54.
Absorption Extension Absorption Bulk 50.00 V Extended Absorption Float Absorption Extension Voltage 1:00 2:00 3:00 4:00 5:00 6:00 time (hrs) Figure 4-3. Absorption extension charging profile. If battery voltage discharges below 50.00 Volts the previous night, Absorption charging will be extended on the next charge cycle as shown in figure 4-3 above. 30 minutes will be added to the normal Absorption duration.
Float Cancel Voltage Absorption Bulk Float cancelled this charge cycle 46.00 V Float Cancel Voltage 1:00 2:00 3:00 4:00 5:00 6:00 time (hrs) Figure 4-5. Float cancelled charging profile If the battery bank discharges below 46.00 Volts the previous night, Float charging stage will be cancelled for the next charge cycle. Figure 4-5 above illustrates this concept. At 0:00 hrs (dawn), battery voltage is below the Float Cancel threshold voltage.
Temperature Compensation All charging settings are based on 25°C (77°F). If the battery temperature varies by 5°C, the charging setting will change by 0.60 Volts for a 48 Volt battery. This is a substantial change in the charging of the battery, and the use of the Remote Temperature Sensor (RTS) is recommended to adjust charging to the actual battery temperature. The need for temperature compensation depends on the temperature variations, battery type, how the system is used, and other factors.
4.3 Push-Button The following functions can be enabled with the pushbutton (located on the front cover): PUSH • Reset from certain errors or faults. • Reset the battery service indication if this has been activated in custom settings. A new service period will be started, and the flashing LEDs will stop blinking. If the battery service is performed before the LEDs begin blinking, the pushbutton must be pushed at the time when the LEDs are blinking to reset the service interval and stop the blinking.
4.4 LED Indications Valuable information is provided by the three LEDs visible through 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 Status // Faults & Alarms.
Battery State-of-Charge LED Indications G G+Y Y Y+R R 80% to 95% SOC 60% to 80% SOC 35% to 60% SOC 0% to 35% SOC battery is discharging Refer to the Specifications (Section 9.0) for the State-of-Charge voltages. Note that because these State-of-Charge LED displays are for all battery types and system designs, they are only approximate indications of the battery charge state.
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.
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 controller 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.
Alarms High Temperature Current Limit 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. The TriStar MPPT 600V is designed to operate at full rated current at the maximum ambient temperature. This alarm indicates that there is insufficient airflow and that the heatsink temperature is approaching unsafe limits.
5.0 Networking and Communication 5.1 Introduction The TriStar MPPT 600V provides several communication options. The TriStar MPPT 600V uses a proprietary protocol for the MeterBusTM network and the non-proprietary open standard MODBUSTM and MODBUS TCP/IPTM protocols for RS-232, EIA-485, and ethernet networks. Additionally, HTTP, SMTP, and SNMP are supported for web page, email, and network message support.
5.2 Morningstar MeterBusTM Morningstar’s proprietary MeterBusTM protocol allows communication between compatible Morningstar products. Use a MeterBusTM network to: • display select net system data for multiple TriStar / TriStar MPPT / TriStar MPPT 600V systems** • communicate with a TriStar Meter 2 -600V, a TriStar Meter 2 or TriStar Remote Meter 2 • communicate with a Relay Driver or other compatible Morningstar accessories (see section 2.
5.3 Serial RS-232 The serial port connection on the TriStar MPPT 600V is a standard 9-pin isolated RS-232 port. See figure 3-5 for the port location.The TriStar MPPT 600V communicates through the serial port via the open standard MODBUSTM protocol.
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 600V 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.
5.4 EIA-485 (formerly RS-485) NOTE: The RS-232 and EIA-485 ports share hardware. Both ports cannot be used simultaneously. EIA-485 is a networking standard for serial communication between multiple devices on a bus. The TriStar MPPT 600V communicates over an EIA-485 network via the open standard MODBUSTM protocol.
5.5 Ethernet ! CAUTION: Risk of Tampering The TS-MPPT-600V does not feature built-in network security. It is the responsibility of the user or network administrator to place the TS-MPPT-600V behind a network firewall to prevent unauthorized access. ! PRUDENCE : Risque de tentative d’altération Le TS-MPPT-600V ne comporte pas de sécurité réseau intégrée. Il incombe à l’utilisateur ou à l’administrateur du réseau de placer le TS-MPPT-600V derrière un pare-feu réseau afin d’empêcher l’accès non autorisé.
Ethernet Cross-over Cable Figure 5-3. Ethernet network diagrams. Factory Default Network Settings DHCP enabled Live View Web Address http://tsmppt + serial number ** IP 192.168.1.253 (if DHCP is not enabled) Subnet Mask 255.255.255.0 Gateway 192.168.1.1 Primary DNS Server 169.254.1.1 TM MODBUS TCP/IP Port 502 ** The Live View web address is unique to each controller. If the TriStar MPPT serial number is 09501234, then the Live View address is: http://tsmppt09501234.
Custom Settings The TriStar MPPT Setup Wizard in MSViewTM provides an interface to adjust all operating parameters. Morningstar’s MSViewTM PC software can connect to any TriStar MPPT 600V on the Ethernet network or through a RS-232 serial connection. Refer to the help documentation included with MSViewTM for more information.
SNMP For telecom and industrial applications that require SNMP monitoring of deployed systems, the TriStar MPPT will behave as an SNMP agent and supports the following commands: TRAP GET GETNEXT A link to the agent Management Information Base file (*.MIB) is available on the TriStar MPPT 600V Live View Network Settings page.
6.0 Trouble-Shooting Battery Charging and Performance Issues Problem: No LED indications, controller does not appear to be powered Solution: With a multi-meter, check the voltage at the battery terminals on the TriStar MPPT 600V. Battery voltage must be 16* vdc or greater. If the voltage on the battery terminals of the controller is between 16 and 72 vdc, and no LEDs are lit, contact your authorized Morningstar dealer for service. If no voltage is measured, check wiring connections, fuses, and breakers.
Network and Communication Issues Problem: Cannot connect to the controller via RS-232 Solution: Check the following: • The RS-232 cable is straight-through, not a Null Modem (cross-over) • If using a serial-USB adapter, verify that the adapter software is installed and a serial COM port has been mapped. Check the activity light on the USB adapter if it has one. If there is no activity, the wrong COM port has been chosen or there is a configuration issue with the adapter.
7.0 Maintenance and Service Your TriStar MPPT 600V will provide years of reliable and trouble-free service. The unit contains no electromechanical parts such as relays or cooling fans that can wear out and fail. Additionally, there are no user-serviceable parts inside. 7.1 IMPORTANT SAFETY INSTRUCTIONS This section contains important safety, installation and operating instructions for the TriStar MPPT 600V solar controller.
• Déconnectez toutes les sources d’alimentation du contrôleur avant d’installer ou de régler le TriStar MPPT. • Le TriStar MPPT ne contient aucun fusible ou interrupteur. Ne tentez pas de réparer. Installation Safety Precautions WARNING: This unit is not provided with a GFDI device. This charge controller must be used with an external GFDI device as required by the Article 690 of the National Electrical Code for the installation location. • Mount the TriStar MPPT 600V indoors.
A means of disconnecting all power supply poles must be provided. These disconnects must be incorporated in the fixed wiring. Using the TriStar MPPT HV ground terminal (in the wiring compartment), a permanent and reliable means to the earth ground must be established. The grounding conductor must be secured against any accidental detatchment. The knock-outs in the TriStar MPPT 600V wiring compartment must protect wires with conduit or rings.
Le contrôleur TriStar MPPT 600V doit être installé par un technicien qualifié conformément aux règlementations électriques du pays où est installé le produit. Un moyen d’assurer la déconnexion de tous les pôles de l’alimentation doit être fourni. Cette déconnexion doit être incorporée dans le câblage fixe. À l’aide de la borne de mise à la masse du TriStar MPPT 600V (dans le compartiment de câblage), un moyen permanent et fiable de mise à la terre doit être fourni.
7.2 Maintenance Schedule Table 7-1 below lists the recommended maintenance schedule to keep your TriStar MPPT 600V performing optimally. WARNING: Shock Hazard Disconnect all power sources to the controller before removing the wiring box cover. Never remove the cover when voltage exists on the TriStar MPPT 600V power connections. AVERTISSEMENT: Risque de décharge électrique Déconnectez toutes les sources d’alimentation du contrôleur avant d’enlever le couvercle du boîtier de câblage.
7.3 Removing the Power Stage for Service Step 1 - Disconnect Power from all sources All sources of power must be disconnected from the unit before proceeding. Open disconnects and remove fuses as needed. Step 2 - Remove the wiring box cover Remove the four (4) screws that secure the wiring box cover to the wiring box. Set the cover and screws aside.
7.4 Warranty Service Procedure In the unlikely event that your TriStar MPPT 600V requires warranty service or repair, the following steps should be followed to ensure prompt service: 1. Take note of the exact issue. Write down any error LED indications and other symptoms. 2. Check troubleshooting section 6.0 in this manual and the online technical resources on our websites at: http://www.morningstarcorp.com/ 3.
8.0 Warranty The TriStar MPPT 600V charge controller is 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 problem with the controller.
9.0 Specifications Electrical TS-MPPT-60-600V-48 TS-MPPT-60-600V-48DB 48 volts 48 volts Nominal System Voltage Maximum Battery Current 60 amps Maximum Solar Input Voltage 600 volts dc 60 amps Battery Operating Voltage Range 16 - 72 volts dc Nominal Maximum Input Power* 3200 watts Voltage Accuracy ≤ 0.1 % ± 100 mV 600 volts dc 16 - 72 volts dc 3200 watts ≤ 0.1 % ± 100 mV Self consumption (tare loss) 2-3.5 watts 2-3.
Battery Charging Status LEDs LED Indication Battery Charging Status Green Flashing (fast) - 2 to 3 times per second 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 53.2 Volts ≤ Vbattery Green & Yellow 52.0 Volts ≤ Vbattery < 53.2 Volts Yellow 50.8 Volts ≤ Vbattery < 52.0 Volts Yellow & Red 48.0 Volts ≤ Vbattery < 50.8 Volts Red Vbattery < 48.
Environmental Ambient Temperature Range -40 °C to +45 °C Storage Temperature -55 °C to +85 °C Humidity 100% N.C.
De-ratings Battery Current vs. Array Voltage Battery Current (Amps) 60 OVERVOLTAGE 0 0 200 425 525 600 Array Voltage (Volts) Figure 9-1. Battery Current vs.
Certifications RoHS UL1741 INVERTERS, CONVERTERS, AND CONTROLLERS AND INTERCONNECTION SYSTEM EQUIPMENT FOR USE WITH DISTRIBUTED ENERGY SOURCES, FIRST EDITION, REVISION THROUGH AND INCLUDING NOV 7, 2005 3094762 CSA C22.2 No. 107.
2% Voltage Drop Charts for 75°C Stranded Copper Wire 1-Way Wire Distance (feet), 48 Volt System 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 Amps 89.6 97.8 107.5 119.5 134.4 153.6 179.2 215.1 0 71.0 77.5 85.2 94.7 106.6 121.8 142.1 170.5 2 44.7 48.7 53.6 59.6 67.0 76.6 89.3 107.2 4 28.1 30.7 33.8 37.5 42.2 48.2 56.3 67.5 6 17.7 19.3 21.2 23.5 26.5 30.3 35.3 42.4 8 11.1 12.2 13.4 14.9 16.7 19.1 22.3 26.7 10 7.0 7.6 8.4 9.3 10.5 12.0 14.0 16.8 12 4.4 4.8 5.3 5.8 6.6 7.
2% Voltage Drop Charts for 75°C Solid Copper Wire 1-Way Wire Distance (feet), 48 Volt System 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 Amps 111.2 121.3 133.5 148.3 166.8 190.6 222.4 266.9 0 88.2 96.2 105.8 117.6 132.3 151.2 176.4 211.7 2 55.4 60.5 66.5 73.9 83.2 95.1 110.9 133.1 4 34.9 38.0 41.9 46.5 52.3 59.8 69.8 83.7 6 21.9 23.9 26.3 29.2 32.9 37.6 43.9 52.6 8 13.8 15.1 16.6 18.4 20.7 23.7 27.6 33.1 10 8.7 9.5 10.4 11.6 13.0 14.9 17.4 20.8 12 5.5 6.0 6.5 7.3 8.
2% Voltage Drop Charts for 90° Stranded Copper Wire 1-Way Wire Distance (feet), 48 Volt System 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 Amps 89.6 97.8 107.5 119.5 134.4 153.6 179.2 215.1 0 71.0 77.5 85.2 94.7 106.6 121.8 142.1 170.5 2 44.7 48.7 53.6 59.6 67.0 76.6 89.3 107.2 4 28.1 30.7 33.8 37.5 42.2 48.2 56.3 67.5 6 17.7 19.3 21.2 23.5 26.5 30.3 35.3 42.4 8 11.1 12.2 13.4 14.9 16.7 19.1 22.3 26.7 10 7.0 7.6 8.4 9.3 10.5 12.0 14.0 16.8 12 4.4 4.8 5.3 5.8 6.6 7.
2% Voltage Drop Charts for 90°C Solid Copper Wire 60 Amps 1-Way Wire Distance (feet), 48 Volt System 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 Amps 111.2 121.3 133.5 148.3 166.8 190.6 222.4 266.9 0 88.2 96.2 105.8 117.6 132.3 151.2 176.4 211.7 2 55.4 60.5 66.5 73.9 83.2 95.1 110.9 133.1 4 34.9 38.0 41.9 46.5 52.3 59.8 69.8 83.7 6 21.9 23.9 26.3 29.2 32.9 37.6 43.9 52.6 8 13.8 15.1 16.6 18.4 20.7 23.7 27.6 33.1 10 8.7 9.5 10.4 11.6 13.0 14.9 17.4 20.8 12 5.5 6.0 6.
This product contains the lightweight IP (lwIP) networking stack, which has been incorporated under the following license: Copyright (c) 2001-2004 Swedish Institute of Computer Science. All rights reserved. THIS SOFTWARE IS PROVIDED BY THE AUTHOR "AS IS" AND ANY EXPRESS OR IMPLIED WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED.
