TRISTAR MPPT 600V TM Solar Charging System Controller Installation, Operation and Maintenance Manual For the most recent manual revision, see the version at: www.morningstarcorp.com TrakStar TM Solar Battery Charger with Maximum Power Point Tracking Technology www.morningstarcorp.
Table of Contents Dimensions in Inches [Millimeters] 1.0 Important Safety Instructions 2.0 Getting Started 11 11 12 13 2.5 Optional Accessories 17 18 3.
Table of Contents (Cont.) 6.0 Troubleshooting 6.1 Battery Charging and Performance Issues 6.2 Network and Communications Issues 7.0 Maintenance and Service 1.0 Important Safety Instructions 66 66 67 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: 69 7.
Informations de Sécurité • Lisez toutes les instructions et les avertissements figurant dans le manuel avant de commencer l’installation. • Le TriStar MPPT 600V ne contient aucune pièce réparable par l’utilisateur. Ne démontez pas ni ne tentez de réparer le contrôleur. AVERTISSEMENT: RISQUE DE CHOC ÉLETRIQUE. NON ALIMENTATION OU AUX BORNES D’ACCESSOIRES SONT ISOLÉS ÉLECTRIQUEMENT DE L’ENTRÉE DE C.C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION DANGEREUSE SOLAIRE.
• 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: Le contrôleur TriStar MPPT 600V 600V600V 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.
• Des gaz explosifs de batterie peuvent être présents pendant la charge. Assurez-vous qu’une ventilation suffisante évacue les gaz. • Ne fumez jamais dans la zone des batteries • En cas de contact de l’électrolyte avec la peau, lavez avec du savon et de l’eau. En cas de contact de l’électrolyte avec les yeux, rincez abondamment avec de l’eau fraîche et consultez un médecin. • Assurez-vous que le niveau d’électrolyte de la batterie est correct avant de commencer la charge.
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.
1 - Heatsink Aluminum heatsink to dissipate controller heat (the TriStar MPPT 600V is 100% passively cooled for reliability) 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
Recommended Tools: 3.0 Installation • • • • 3.1 General Information WARNING: Equipment Damage or Risk of Explosion Never install the TriStar MPPT 600V in an enclosure with vented/flooded batteries. Battery fumes are flammable and will corrode and destroy the TriStar MPPT 600V circuits. ! CAUTION: Equipment Damage When installing the TriStar MPPT 600V in an enclosure, ensure sufficient ventilation. Installation in a sealed enclosure will lead to over-heating and a decreased product lifetime.
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 knock-out 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 Communication Wiring 12 Battery Wiring Solar Wiring Figure 3-6. Wiring pass-through paths between multiple controllers 11 3.4 Controller Preparation (TS-MPPT-60-600V-48 and TS-MPPT-60-600V-48-DB) 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.
Use a #2 Phillips screw driver to remove the four (4) screws that secure the wiring box cover as shown in figure 3-7 below. 3 1 2 Figure 3-8. Remove the Wiring Divider Figure 3-7. Remove the wiring box cover 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.
Step 3 - Remove the Knock-Outs Plan the routing of each cable 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 from power conductors. 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.
5. Insert a #10 screw (included) into the top pilot hole. Do not tighten the screw completely. Leave a 1/4” (6 mm) gap between the mounting surface and screw head. 6. Carefully align the keyhole on the TriStar MPPT 600V with the screw head. Slide the TriStar MPPT 600V down over the keyhole. Check for vertical plumb with a level. 7. Mark four (4) mounting hole locations in the wiring box. 8. Remove the controller and drill 3/32” (2.5 mm) holes at the drill marks. 9.
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.
5. Connect the solar (-) wire to the solar (-) terminal on the TriStar MPPT 600V. 6. Replace the Wiring Divider (removed in Step 2 on page 24) over the solar wires, and secure it with the M4 screw provided. 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.
AVERTISSEMENT: Risque d’endommagement Assurez-vous que la connexion solaire est effectuée avec la polarité correcte. Activez le coupe-circuit/ interrupteur de réseau solaire et mesure la tension sur les câbles ouverts AVANT la connexion au TriStar MPPT 600V. Déconnectez le coupe-circuit/interrupteur solaire avant le câblage sur le contrôleur. 3. Only route high voltage solar circuit conductors in the high voltage wiring zone and low voltage battery and network conductors within the low voltage zone.
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 on p. 13). 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.
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 56.00 54.80 off-off-on 2 - Sealed* 56.60 54.
NOTE: Conductors identified by the color combination green/yellow shall only be used for earthing conductors. 3.9 Power-up and Commissioning Step 11 - Power Up (TS-MPPT-60-600V-48 and TS-MPPT-60-600V-48-DB) Use a copper wire to connect the grounding terminal in the wiring box - and any other dead metallic components - to earth ground. Per NEC 690.45 and NEC Table 250.
4.2 Battery Charging Information 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.
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 gasing of a fully charged battery. The purpose of float is to protect the battery from long-term overcharge.
Preparation for Equalization First, confirm that all of the system loads are rated for the equalization voltage. Consider that at 0°C (32°F) the equalization voltage will reach 67.00 Volts for L-16 batteries with a temperature sensor installed. Disconnect any loads at risk of damage due to the high input voltage. If Hydrocaps are used, be sure to remove them before starting an equalization. Replace the Hydrocaps with standard battery cell caps. The Hydrocaps can get very hot during an equalization.
Absorption Extension Absorption Bulk Extended Absorption Float Cancel Voltage Float Absorption Bulk Float cancelled this charge cycle 50.00 V Absorption Extension Voltage 1:00 2:00 3:00 4:00 49.20 V 5:00 6:00 Float Cancel Voltage time (hrs) 1:00 Figure 4-2. Absorption extension charging profile. Float Time-Out Absorption Float Bulk 3:00 4:00 5:00 6:00 time (hrs) Figure 4-4. Float cancelled charging profile If battery voltage discharges below 50.
4.3 Push-button Temperature Compensation The following functions can be enabled with the pushbutton (located on the front cover): 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.
4.4 LED Indications Battery State-of-Charge 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.
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.
5.0 Networking and Communication 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.
5.2 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 600V 600V/ 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.
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.
5.5 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.
Custom Settings • Charge stage regulation timers for Absorption, Float, Equalize The TriStar MPPT 600V 600VSetup 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.
6.0 Troubleshooting WARNING: RISK OF ELECTRICAL SHOCK. NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROM DC INPUT, AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN FAULT CONDITIONS, BATTERY COULD BECOME OVER-CHARGED. TEST BETWEEN ALL TERMINALS AND GROUND BEFORE TOUCHING. AVERTISSEMENT: RISQUE DE CHOC ÉLETRIQUE. NON ALIMENTATION OU AUX BORNES D’ACCESSOIRES SONT ISOLÉS ÉLECTRIQUEMENT DE L’ENTRÉE DE C.C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION DANGEREUSE SOLAIRE.
Problem: Cannot connect to the controller via Ethernet Solution: See the, “Morningstar Communications Document”, available at: http://support.morningstarcorp.com “What Are You Looking For”: All Documents “Choose Product”: TS-MPPT 600V 7.0 Maintenance and Service 7.1 Important Safety Instructions SAVE THESE INSTRUCTIONS. This manual contains important safety, installation and operating instructions for the TriStar MPPT 600V solar controller.
• External solar and battery disconnects are required. • Disconnect all sources of power to the controller before installing or adjusting the TriStar MPPT 600V. • There are no fuses or disconnects inside the TriStar MPPT 600V Do not attempt to repair. Informations de Sécurité • Lisez toutes les instructions et les avertissements figurant dans le manuel avant de commencer l’installation. • Le TriStar MPPT 600V ne contient aucune pièce réparable par l’utilisateur.
• Utilisez des conducteurs et des coupe-circuits de dimensions adaptées. • La borne de mise à la terre se trouve dans le compartiment de câblage et est identifiée par le symbole ci-dessous estampillé dans le boit: CAUTION: When replacing batteries, proper specified number, sizes types and ratings based on application and system design PRUDENCE: Lorsque le remplacement des piles, utilisez correctement nombre spécifié, tailles, types et les évaluations basées sur conception de système et d’application.
• Débrancher la source de charge avant de brancher ou dis-reliant les bornes de la batterie. • Utilisez des outils isolés et évitez de placer des objets métalliques dans la zone de travail. • Déterminer si batterie repose par inadvertance. Dans l’affirmative, supprimer la source du contact avec le sol. Contact avec n’importe quelle partie d’une batterie mise à la terre peut entraîner un choc électrique.
8.0 Warranty and Claim Procedure WARRANTY CLAIM PROCEDURE WARRANTY LIMITED WARRANTY - Morningstar Solar Controllers and Inverters 1. Before proceeding, please refer to product manual, including troubleshooting section. All Morningstar Professional SeriesTM products, except the SureSineTM inverter, are warrantied to be free from defects in materials and workmanship for a period of FIVE (5) years from the date of shipment to the original end user.
Battery Charging Status LEDs 9.0 Technical Specifications Electrical TS-MPPT-60-600V-48 TS-MPPT-60-600V-48-DB Nominal System Voltage Maximum Battery Current 48 Volts 60 Amps Maximum Solar Input Voltage Maximum Operating Input Current 600 Volts dc 15 Amps Battery Operating Voltage Range 16 - 72 Volts dc 48 Volts 60 Amps (63A breaker included) 600 Volts dc 15 Amps 16 - 72 Volts dc Nominal Maximum Input Power* Voltage Accuracy Self consumption (tare loss) Transient Surge Protection 3200 Watts ≤ 0.
10.0 Appendix Environmental Operating Altitude Below 2000 meters Ambient Temperature Range Storage Temperature Humidity Enclosure -40°C to +45°C -55°C to +85°C 100% N.C. IP20 Type 1 (indoor & vented) De-ratings Battery Current vs.
Output Power vs. Array Input Voltage Battery Current vs.
2% Voltage Drop Charts for 75°C Stranded Copper Wire Efficiency 1-Way Wire Distance (feet), 48 Volt System 200 Vmp, 52 Vbatt 60 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 7.5 8.8 10.5 14 2.8 3.
2% Voltage Drop Charts for 75°C Solid Copper Wire 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 1-Way Wire Distance (feet), 48 Volt System 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.
2% Voltage Drop Charts for 90°C Solid Copper Wire This product contains the lightweight IP (lwIP) networking stack, which has been incorporated under the following license: 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.
