Morningstar TriStar MPPT 600V User manual

Installation and Operation Manual
Solar - Wind Charging System Controller
www.morningstarcorp.com
Solar-Wind Battery Charger with
TrakStarTM Maximum Power Point Tracking Technology
Models:
TS-MPPT-60-600V-48-DB-TR
TS-MPPT-60-600V-48-DB-TR-GFPD
MAXIMUM POWER POINT TRACKING
TriStar MPPT
600V
TM
with
Off-grid / Grid-tie
Transfer Switch

36.40
[
925 ]
35.57
[ 904 ]
8.70
[ 221 ]
1.35
[ 34 ]
5.25
[ 133 ]
6.10
[ 155 ]
2.47
[ 63 ]
11.60
[ 295 ]
9.39
[ 239 ]
1.10
[28 ] 6.50
[ 165 ]
3.25
[ 83 ]
4.40
[112]
1.40
[36 ]
3.30
[84 ]
1.00
[ 25 ]
14.17
[ 360 ]
1.15
[ 29 ]
6.80
[173 ]
12.80
[ 325 ]
14.17
[ 360 ]
1.15
[29 ]
4.50
[ 114]
12.80
[ 325 ]
.90
[ 23 ] 1.30
[33 ]
.80
[20 ]
1.30
[33 ]
2.02
[ 51 ]
1.04
[26 ]
.90
[23 ] 1.30
[33 ]
1.04
[ 26 ] 2.02
[ 51 ]
1.30
[ 33 ]
.90
[23 ]
12 PLACES
O 0.21 [ 5 ]
2.60
[66 ]
14.03
[ 356 ]
14.17
[ 360 ]
1.04
[ 26 ]
3.06
[ 78 ]
1.35
[ 34 ]
2.83
[ 72 ]
3.83
[ 97 ]
4.83
[ 123 ]
5.83
[ 148 ]
7.35
[ 187 ]
.78
[ 20 ]
1.30
[ 33 ]
2.82
[ 72 ]
5.86
[ 149 ]
3.34
[ 85 ]
3.40
[86 ]
6.20
[ 157 ]
Dimensions in inches [millimeters]

TABLE OF CONTENTS
1.0 Important Safety Instructions 4
2.0 Getting Started 8
2.1 Overview 8
2.2 Regulatory Information 10
2.3 Versions and Ratings 11
2.4 Features 12
2.5 Optional Accessories 15
3.0 Installation 16
3.1 General Information 16
3.2 Wiring Zones 17
3.3 Conduit Knock-outs and Wire Routing 19
3.4 Controller Installation 21
4.0 Operation 39
4.1 Using the Transfer Switch 39
4.2 TrakStarTM MPPT Technology 40
4.3 Battery Charging Information 41
4.4 GFPD-600V Operation 48
4.5 Push-button 49
4.6 LED Indications and Audible Warnings 50
4.7 Protections, Faults & Alarms 52
5.0 Networking and Communication 55
5.1 Introduction 55
5.2 Morningstar MeterBusTM 56
5.3 Serial RS-232 57
5.4 EIA-485 (formerly RS-485) 59
5.5 Ethernet 60
6.0 Testing and Troubleshooting 64
7.0 Maintenance and Service 67
7.1 Important Safety Instructions 67
7.2 Maintenance Schedule 71
8.0 Warranty and Claim Procedure 72
9.0 Technical Specications 74

4Important Safety Instructions
SAVE THESE INSTRUCTIONS
This manual contains important safety, installation and operating instructions for the
TS-MPPT-600V-TR 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.
!CAUTION:
Indicates a critical procedure for safe and proper operation of the controller.
NOTE:
Indicates a procedure or function that is important for the safe and proper operation
of the controller.
AVERTISSEMENT :
Indique une condition potentiellement dangereuse. Faites preuve d’une prudence
extrême lors de la réalisation de cette tâche.
!PRUDENCE :
Indique une procédure critique pour l’utilisation sûre et correcte du contrôleur.
REMARQUE :
Indique une procédure ou fonction importante pour l’utilisation sûre et correcte du
contrôleur.
Safety Information
• Read all of the instructions and cautions in the manual before beginning installation.
• There are no user serviceable parts inside the TS-MPPT-600V-TR. Do not disassemble or
attempt to repair the controller.
• Disconnect all sources of power to the controller before installing or adjusting the
TS-MPPT-600V-TR.
• There are no fuses or disconnects inside the TS-MPPT-600V-TR. Do not attempt to repair.
• Install external fuses/breakers as required.
Informations de Sécurité
• Liseztouteslesinstructionsetlesavertissementsgurantdanslemanuelavantdecom-
mencer l’installation.
• Le TS-MPPT-600V-TR ne contient aucune pièce réparable par l’utilisateur. Ne démontez
pas ni ne tentez de réparer le contrôleur.
• Déconnectez toutes les sources d’alimentation du contrôleur avant d’installer ou de régler
le TS-MPPT-600V-TR.
• Le TS-MPPT-600V-TR ne contient aucun fusible ou interrupteur. Ne tentez pas de réparer.
• Installez des fusibles/coupe-circuits externes selon le besoin.
1.0 Important Safety Instructions

5TriStar MPPT-600V-TR Operator's Manual
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 TS-MPPT-600V-TR indoors. Prevent exposure to the elements and do not allow
water to enter the controller.
• Install the TS-MPPT-600V-TR in a location that prevents casual contact. The
TS-MPPT-600V-TR heatsink can become very hot during operation.
• Use insulated tools when working with batteries.
• Avoid wearing jewelry during installation.
• The battery bank must be comprised of batteries of same type, make, and age.
• Do not smoke in the vicinity of the battery bank.
• Power connections must remain tight to avoid excessive heating from a loose connection.
• Use properly sized conductors and circuit interrupters.
• Thegroundingterminalislocatedinthewiringcompartmentandisidentiedbythesym-
bol below.
Ground Symbol
• This charge controller is to be connected to DC circuits only. These DC connections are
identiedbythesymbolbelow.
Direct Current Symbol
TheTS-MPPT-600V-TRcontrollermustbeinstalledbyaqualiedtechnicianinaccordancewith
electrical regulations of the country where the product is installed.
A means of disconnecting all power supply poles must be provided. These disconnects must
beincorporatedinthexedwiring.UsingtheTS-MPPT-600V-TR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 TS-MPPT-600V-TR wiring compartment must protect wires with conduit or
rings.

6Important Safety Instructions
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 TS-MPPT-600V-TR à l’intérieur. Empêchez l’exposition aux éléments et la pé-
nétration d’eau dans le contrôleur.
• Installer le TS-MPPT-600V-TR dans une situation qui empêche le contact occasionnel. Le
radiateur TS-MPPT-600V-TR peut devenir très chaud pendant le fonctionnement.
• Utilisez des outils isolés pour travailler avec les batteries.
• Évitez le port de bijoux pendant l’installation.
• Le groupe de batteries doit être constitué de batteries du même type, fabricant et âge.
• Ne fumez pas à proximité du groupe de batteries.
• Les connexions d’alimentation doivent rester serrées pour éviter une surchauffe excessive
d’une connexion desserrée.
• 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identiée
par le symbole ci-dessous.
•Cecontrôleurdechargenedoitêtreconnectéqu’àdescircuitsencourantcontinu.Ces
connexionsCCsontidentiéesparlesymboleci-dessous.
LecontrôleurTS-MPPT-600V-TRdoitêtreinstalléparuntechnicienqualié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xe.
À l’aide de la borne de mise à la masse du TS-MPPT-600V-TR (dans le compartiment de
câblage),unmoyenpermanentetabledemiseàlaterredoitêtrefourni.Laxationdelamise
àlaterredoitêtrexéecontretoutdesserrageaccidentel.
Les ouvertures d’entrée au compartiment de câblage du TS-MPPT-600V-TR doivent être
protégées avec conduit ou anneaux.

7TriStar MPPT-600V-TR Operator's Manual
WARNING: A battery can present a risk of electrical shock or burn from large amounts of short-
circuitcurrent,re,orexplosionfromventedgases.Observeproperprecautions.
 CAUTION:Whenreplacingbatteries,useproperlyspecied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.
AVERTISSEMENT: Une batterie peut présenter a risque de choc électrique ou de brûlure de
grandes quantités de court-circuit curlouer, incendie ou explosion de ventilé gaz.
PRUDENCE: Observer les précautions adéquates. Quand remplacer l'utilisation de piles cor
rectement spécifié tailles, types, et cotes fondées sur l'application et conception des systèmes.
PRUDENCE: Élimination appropriée des batpiles est nécessaire. Se ré férer au local
règlements ou codes pour exigentments.
About this Manual:
This manual provides detailed installation and usage instructions for the TS-MPPT-600V-TR
controller.Onlyqualiedelectriciansandtechnicianswhoarefamiliarwithsolarsystemdesign
and wiring practices should install the TS-MPPT-600V-TR. The usage information in this manual
is intended for the system owner/operator.

8Getting Started
Getting Started2.0
2.1 Overview
Thank you for selecting the TS-MPPT-600V-TR solar charge controller. Both models are
specialized components designed for use in grid-tie / off-grid systems. These products feature a
transfer switch which allows the user to toggle connections between a grid-tie inverter and
battery bank storage. The diagram below shows the basic dual-mode functionality of the
product.
SOLAR
ARRAY
Input (+) and
(-) Wires
TS-600V-MPPT-TR
Battery
Disconnect
Main Input
Disconnect
Battery
Bank
Grid-tie
Inverter
Transfer
Switch
GFPD
PV and battery
(+) and (-)
connections
PV and battery
(+) and (-)
connections

9TriStar MPPT-600V-TR Operator's Manual
The TS-MPPT-600V-TR with TrakStarTM MPPT Technology is an advanced maximum power point
trackingsolarbatterycharger.Thecontrollerfeaturesasmarttrackingalgorithmthatndsand
maintains operation at the solar array peak power point, maximizing energy harvest.
The TS-MPPT-600V-TR battery charging process has been optimized for long battery life and
improved system performance. Self-diagnostics and electronic error protections prevent damage
when installation mistakes or system faults occur. The controller also features eight (8) adjustable
settings switches, several communication ports, and terminals for remote battery temperature
and voltage measurement.
Please take the time to read this operator’s manual and become familiar with the controller. This
will help you make full use of the many advantages the TS-MPPT-600V-TR can provide for your
PV system.
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 protec-
tion 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. However, there is
no guarantee that interference will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception, which can be determined by turning
the equipment on and off, the user is encouraged to try to correct the interference by one or more
of the following measures:
• Re-orient or re-locate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
• Consult the dealer or an experienced radio/TV technician for help.
This Class B digital apparatus complies with Canadian ICES-003.
Cet appareil numerique de la classe B est conforme a la norme NMB-003 du Canada.

10 Getting Started
2.2 Regulatory Information
NOTE:
This section contains important information for safety and
regulatory requirements.
TheTS-MPPT-600V-TRcontrollershouldbeinstalledbyaqualiedtechnicianaccordingtothe
electrical rules of the country in which the product will be installed.
TS-MPPT-600V-TR controllers comply with the following EMC standards:
• Immunity:EN61000-6-2:2005
• Emissions:EN55022:22007withA1andA3ClassB1
• Safety:EN60335-1andEN60335-2-29(batterychargers)
A means shall be provided to ensure all pole disconnection from the power supply. This discon-
nectionshallbeincorporatedinthexedwiring.
Using the TS-MPPT-600V-TR grounding terminal (in the wiring compartment), a permanent and
reliable means for grounding shall be provided. The clamping of the earthing shall be secured
against accidental loosening.
The entry openings to the TS-MPPT-600V-TR wiring compartment shall be protected with conduit
or with a bushing.
FCC requirements:
This device complies with Part 15 of the FCC rules. Operation is subject to the following two
conditions: (1) This device may not cause harmful interference, and (2) this device must accept
any interference received, including interference that may cause undesired operation. Changes
ormodicationsnotexpresslyapprovedbyMorningstarforcompliancecouldvoidtheuser’s
authority to operate the equipment.

11TriStar MPPT-600V-TR Operator's Manual
2.3 Versions and Ratings
There are two versions of TS-MPPT-600V-TR controller:
TS-MPPT-60-600V-48-DB-TR
• enhanced wiring Disconnect Box (DB) with battery disconnect breaker
• Maximum 60 amps continuous battery current
• 48 volt DC systems
• Maximum 600 volt DC solar input voltage
• RS-232, EIA-485, MeterBusTM, and Ethernet communication ports
TS-MPPT-60-600V-48-DB-TR-GFPD
• enhanced wiring Disconnect Box (DB) with battery disconnect breaker
• Maximum 60 amps continuous battery current
• 48 volt DC systems
• Maximum 600 volt DC solar input voltage
• RS-232, EIA-485, MeterBusTM, and Ethernet communication ports
• Includes the GFPD-600V ground-fault protection device

12 Getting Started
2.4 Features
The features of the TS-MPPT-600V-TR-GFPD models is shown in Figure 2-1 below. An
explanation of each feature follows.
Figure 2-1. TS-MPPT-600V-TR-GFPD Features

13TriStar MPPT-600V-TR Operator's Manual
TS-MPPT-60-600V-48-DB-TR Box
1 - Heatsink
Aluminum heatsink to dissipate controller heat (the TS-MPPT-600V-TR 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congureoperationoftheTS-MPPT-600V-TR-DB
5 - MeterBusTM Port
RJ-11 socket for Morningstar MeterBusTM network connections
6 - Ethernet Port
RJ-45 socket for LAN/internet connections
7 - Serial RS-232 Port
9-pin serial connector (female)
8 - EIA-485 Port
Four (4) position screw terminal for EIA-485 bus connections
9 - Battery Breaker [(63A rating), (pre-wired)]
Battery (+) disconnect point
10 - Battery Terminal Blocks
(+) and (-) battery terminal connection points
11. - Grounding Terminal Block
A chassis terminal for system grounding
12 - Solar Terminal Blocks
(+) and (-) solar terminal connection points
13 - Connections Points out to Grid-Tie Inverter Solar Input
14 - Transfer Switch
Controls grid-tie and battery charging modes
15 - LED Indicators
Show battery state-of-charge (SOC) and controller fault conditions
16 - Remote Temperature Sensor Terminals
Connection point for a Morningstar RTS to remotely monitor battery temperature
17. Push-button Switch
Manually reset from an error or fault, also used to start/stop a manual equalization.
18 - Battery Voltage Sense Terminals
Terminals for battery voltage input provide accurate battery voltage measurement

14 Getting Started
19 - Solar Terminal Bridge (yellow)
Isolates high voltage PV wiring from low voltage wiring area
20 - (+) and (-) Solar Power Terminals (pre-wired)
(+) and (-) solar terminal connection points
Optional TS-MPPT-60-600V-48-DB-TR-GFPD Box
21 - Breaker Mounting Plate (removable)
Pre-wired and mounted GFPD sensor and breaker assembly
22 - Ganged Ground-fault Breakers
(+) and (-) leg ground-fault interruption breakers
23 - (+) and (-) Solar Breaker Post Connections [(pre-wired),(underside)]
Connection points for (+) and (-) solar wires
24 - Solar Wiring Aperture
Sensing opening for GFPD control
25 - Auxilliary DIN Rail Mount
Available for DIN mountable equipment
26 - Grounding Terminal Block
A chassis terminal for system grounding
27 - Test / Reset Button
Performs testing and reset functions
28 - Bi-Color LED
Indicates various fault and alarm conditions
29 - GFPD Control and Power Terminals
Terminal connections for GFPD signals and power.

15TriStar MPPT-600V-TR Operator's Manual
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.
TriStar Meter 2-600V; TriStar Remote Meter 2 (Models: TS-M-2-600V; TS-
RM-2)
The TS-M-2-600V mounts directly on the TS-MPPT-600V-TR controller, replacing the blank
metercoveronthewiringboxlid.TheTS-RM-2canbeushmountedinawallorintoastandard
duplex (2-gang) electrical box. A 2 x 16 character display shows system operating information,
error indications, and self-diagnostic information. Four (4) buttons make navigating the meter
menus easy.
TriStar meters connect to the RJ- 11 MeterBusTM port on the TS-MPPT-600V-TR. One (1) meter
can display select full system information when multiple TS-MPPT-600V-TR or other TriStar con-
trollers are connected via a MeterBusTM network.
Meter Hub (HUB-1)
A Morningstar MeterBusTM network with multiple controllers requires a Meter Hub for electrical
isolation. The HUB-1 allows communication between MeterBusTM compatible Morningstar prod-
ucts, including the TS-MPPT-600V-TR controller. DIN rail compatible. See section 5.2 for more
details.
Relay Driver (RD-1)
The Relay DriverTM accessory enables the TS-MPPT-600V-TR to control external devices. Four
(4)relaycontrolportscanbecongured(invariouscombinations)toperformthefollowingtasks:
• generatorcontrol(2-,3-,and4-wirecongurations)
• 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.com or
inquire with your local Morningstar dealer.
EIA-485 / RS-232 Communications Adapter (RSC-1)
Connect one or more TS-MPPT-600V-TR controllers to a PC or to other serial devices using the
EIA-485 adapter. The adapter converts an RS-232 serial interface to EIA-485 compliant bus
signals. An LED shows network activity and errors. DIN rail compatible.

16 Installation
3.1 General Information
WARNING: Equipment Damage or Risk of Explosion
Never install the TS-MPPT-600V-TR in an enclosure with vented/ooded batteries.
Battery fumes are ammable and will corrode and destroy the TS-MPPT-600V-TR
circuits.
!CAUTION: Equipment Damage
When installing the TS-MPPT-600V-TR in an enclosure, ensure sufcient ventilation.
Installation in a sealed enclosure will lead to over-heating and a decreased product
lifetime.
AVERTISSEMENT: Endommagement de l’équipement ou risque d’explosion
N’installez jamais le TS-MPPT-600V-TR dans une enceinte avec des batteries à évent/à
électrolyte liquide. Les vapeurs des batteries sont inammables et corroderont et
détruiront les circuits du TS-MPPT-600V-TR.
!
PRUDENCE: Endommagement de l’équipement
Assurez une ventilation sufsante en cas d’installation du TS-MPPT-600V-TR dans une
enceinte. L’installation dans une enceinte hermétique entraîne une surchauffe et une
réduction de la durée de vie du produit.
The installation is straight-forward, but it is important each step is done correctly and safely. A
mistake can lead to dangerous voltage and current levels. Be sure to carefully follow each in-
struction in this section. READ ALL INSTRUCTIONS FIRST before beginning installation.
The installation instructions are for installation of a negative grounded system. U.S National
Electrical Code (NEC) requirements are noted on occasion for convenience, however the install-
er should have a complete understanding of NEC and UL requirements for photovoltaic installa-
tions.
Installation3.0

17TriStar MPPT-600V-TR Operator's Manual
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. There is overlap in the zones as pictured because
the removable wiring divider separates the high voltage solar wiring and low voltage wiring. Solar
high voltage wiring should be routed below the removable wiring divider. The yellow Solar
Terminal Bridgemustbeproperlyttedinplacebeforemakingthesolarpowerterminal
connections.
The battery wiring and all communication cables must only be routed within the low voltage
wiring zone. After the solar wiring is installed, the wiring divider should be secured in place, and
the battery cables routed above the divider. Detailed installation steps are provided in the
following sections.
NOTE: IfALLeldwiring,includingcommunicationscable,isratedfor600V,wiring
zone separation is not required. In this case, it may be more convenient to remove the
high-low voltage wiring box divider, and terminate conduit that contains mixed voltage
conductors at one point.

18 Installation
High and Low Voltage Wiring Positions - TS-MPPT-600V-TR
Figure 3-1. TS-MPPT-600V-TR / GFPD high and low voltage wiring zones (shaded areas)
600V wiring below
the removable
Wiring Divider
(divider removed)
Low voltage wiring
above the Wiring
Divider
(divider in place)

19TriStar MPPT-600V-TR Operator's Manual
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 TS-MPPT-600V-TR wiring box. Knockout placement
dimensions are on the inside front cover. Figures 3-2 and 3-3 show knock-out types.
The TS-MPPT-600V-TR wiring box provides continuous and separate paths for high
voltage (solar) and low voltage (battery & COM) wiring routing. These allow wiring to pass be-
tween TS-MPPT-600V-TR controllers that are mounted side-by-side without the need for exter-
nalconduittubing.Table3-1identiesthepass-throughknock-outswhichmaybeusedforthis
purpose. Figure 3-6 shows the routing of the high voltage and low voltage wiring paths.
3
8
7
10
4
9
2
2
6
5
5
1
1
1
3
6
11
Figure 3-2. Knock-outs, left , right and back views

20 Installation
3
1
4
Figure 3-3. Knock-outs, bottom view
Item Quantity Trade Size Hole Dimension Circuit(s)
1 2 (Concentric) 1” & 3/4” 1.36“ (34.5 mm) / 1.09” (27.8 mm) Solar (high voltage)
2 2 (Concentric) 1-1/4“ & 1“ 1.72” (43.7 mm) / 1.36“ (34.5 mm) Battery (low voltage)
32 (Concentric) 1-1/4" & 1" 1.72” (43.7 mm) / 1.36“ (34.5 mm) Solar (high voltage)
411 1/2” or M20 7/8” (22.2 mm) Solar (high voltage)
5 1 1/2” or M20 7/8” (22.2 mm) Communication
6 1 3/4” 1.09" (27.8 mm) Communication
7 4 3/4" Solar (high voltage)
8 2 1” 1.36“ (34.5 mm) Battery (low voltage)
9 3 1/2” or M20 0.88” (22.2 mm) Battery
10 2 1/2” or M20 0.88” (22.2 mm) Solar
11 2 3/4” 1.09” (27.8 mm) Solar (high voltage)
** Solar connector mounting hole diameters vary. Wieland Solar DC connectors recommended.
Table 3-1. Knock-out sizes