Morningstar TriStar MPPT Series User manual

Installation, Operation and Maintenance Manual
Solar Charging System Controller
www.morningstarcorp.com
Solar Battery Charger
With
TrakStarTM Maximum Power Point Tracking Technology
MODELS
TS-MPPT-30
TS-MPPT-45
TS-MPPT-60
TRISTAR MPPT TM
For the most recent manual revisions, see the version at:
www.morningstarcorp.com

Dimensions in Inches [Millimeters]

4Important Safety Instructions
SAVE THESE INSTRUCTIONS.
This manual contains important safety, installation and operating instructions for the
TriStar MPPT 150V 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 TriStar MPPT 150V. Do not disassemble
or attempt to repair the controller.
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 CER-
TAIN FAULT CONDITIONS, BATTERY COULD BECOME OVER-CHARGED. TEST BETWEEN
ALL TERMINALS AND GROUND BEFORE TOUCHING.
• External solar and battery disconnects are required.
• Disconnect all sources of power to the controller before installing or adjusting the
TriStar MPPT 150V.
• There are no fuses or disconnects inside the TriStar MPPT 150V Do not attempt to repair.
1.0 Important Safety Instructions

6Important Safety Instructions
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by the symbol below:
Direct Current Symbol
The TriStar MPPT 150V controller must be installed by a qualified technician in accordance with the
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 fixed wiring.
A permanent, reliable earth ground must be established with connection to the wiring compartment
ground terminal.
The grounding conductor must be secured against any accidental detachment. The knock-outs in
the wiring compartment must protect wires with conduit or rubber rings.
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 150V à l’intérieur. Empêchez l’exposition aux éléments et la pénétration
d’eau dans le contrôleur.
• Installez le TriStar MPPT 150V dans un endroit qui empêche le contact occasionnel. Le dissipateur
de chaleur 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.
•/DERUQHGHPLVHjODWHUUHVHWURXYHGDQVOHFRPSDUWLPHQWGHFkEODJHHWHVWLGHQWL¿pHSDUOH
symbole ci-dessous estampillé dans le boit:

8Important Safety Instructions
• Servicing of batteries should be performed, or supervised, by personnel knowledgeable about
batteries, and the proper safety precautions.
• Be very careful when working with large lead-acid batteries. Wear eye protection and have fresh
water available in case there is contact with the battery acid.
• Remove watches, rings, jewelry and other metal objects before working with batteries.
• Wear rubber gloves and boots
•Use tools with insulated handles and avoid placing tools or metal objects on top of batteries.
• Disconnect charging source prior to connecting or dis-connecting battery terminals.
• Determine if battery is inadvertently grounded. If so, remove the source of contact with ground.
Contact with any part of a grounded battery can result in electrical shock. The likelihood of such
a shock can be reduced if battery grounds are removed during installation and maintenance
(applicable to equipment and remote battery supplies not having a grounded supply circuit).
• Carefully read the battery manufacturer’s instructions before installing / connecting to, or removing
batteries from, the TriStar MPPT.
• Be very careful not to short circuit the cables connected to the battery.
• Have someone nearby to assist in case of an accident.
• Explosive battery gases can be present during charging. Be
certain there is enough ventilation to
release the gases.
• Never smoke in the battery area.
• If battery acid comes into contact with the skin, wash with
soap and water. If the acid contacts the
H\HÀRRGZLWKIUHVKZDWHUDQGJHWPHGLFDODWWHQWLRQ
• Be sure the battery electrolyte level is correct before starting charging. Do not attempt to charge a frozen
battery.
• Recycle the battery when it is replaced.
• Entretien des batteries devrait être effectué ou supervisé, par un personnel bien informé sur les
piles et les précautions de sécurité appropriées.
• Soyez très prudent quand vous travaillez avec des grandes batteries au plomb. Portez des lunettes
de protection et ayez de l’eau fraîche à disposition en cas de contact avec l’électrolyte.
• Enlevez les montres, bagues, bijoux et autres objets mé talliques avant de travailler avec des piles.
• Porter des bottes et des gants de caoutchouc
• Utiliser des outils avec poignées isolantes et évitez de placer des outils ou des objets métalliques
sur le dessus de batteries.
• 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.
•'pWHUPLQHUVLEDWWHULHUHSRVHSDULQDGYHUWDQFH'DQVO¶DI¿UPDWLYHVXSSULPHUODVRXUFHGXFRQWDFW
avec le sol. Contact avec n’importe quelle partie d’une batterie mise à la terre peut entraîner un
choc électrique. La probabilité d’un tel choc peut être réduite si des motifs de batterie sont suppri-
més pendant l’installation et maintentretien (applicable à l’équipement et les fournitures de pile de
la télécommande n’ayant ne pas un circuit d’alimentation mise à la terre *).
• Lisez attentivement les instructions du fabricant de la batterie avant d’installer / connexion à ou
retrait des batteries du TriStar MPPT.
• Veillez à ne pas court-circuiter les câbles connectés à la batterie.
• Ayez une personne à proximité qui puisse aider en cas d’accident.

10 Getting Started
Getting Started2.0
2.1 Overview
Thank you for selecting the TriStar MPPT 150V solar charge controller with TrakStarTM MPPT
Technology. The TriStar MPPT 150V (TS-MPPT) is an advanced maximum power point tracking
VRODUEDWWHU\FKDUJHU7KHFRQWUROOHUIHDWXUHVDVPDUWWUDFNLQJDOJRULWKPWKDW¿QGVDQGPDLQWDLQV
operation at the solar array peak power point, maximizing energy harvest.
The TriStar MPPT 150V 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 TriStar MPPT 150V can provide for your
PV system.
2.2 Versions and Ratings
There are three versions of TriStar MPPT 150V controller:
TriStar-MPPT-30
• maximum 30 amps continuous battery current
• 12, 24 and 48 Volt dc systems
• maximum 150 Volt dc solar input voltage
• RS-232 and MeterBusTM communication ports
TriStar-MPPT-45
• maximum 45 amps continuous battery current
• 12, 24 and 48 Volt dc systems
• maximum 150 Volt dc solar input voltage
• RS-232 and MeterBusTM communication ports
TriStar-MPPT-60
• maximum 60 amps continuous battery current
• 12, 24 and 48 Volt dc systems
• maximum 150 Volt dc solar input voltage
• RS-232, EIA-485, MeterBusTM, and Ethernet communication ports

12 Getting Started
1 - Heatsink
Aluminum heatsink to dissipate controller heat
2 - Mounting Hanger
Keyhole slot for mounting
3 - Settings Switches
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4 - Battery Positive Terminal (red)
Power connection for Battery (+)
5 - Remote Temperature Sensor Terminals
Connection point for a Morningstar RTS (optional) to remotely monitor battery temperature
6 - LED Indicators
Three state of charge (SOC) LED indicators show charging status and controller faults
7 - MeterBusTM Port
RJ-11 socket for Morningstar MeterBusTM network connections
8 - Battery Voltage Sense Terminals
Terminals for battery voltage input provide accurate battery voltage measurement
9 - Ground Terminal
A chassis ground terminal for system grounding
10 - Ethernet Port
RJ-45 socket for LAN/internet connections (TS-MPPT-60 model only)
11 - Wiring Box with Conduit Knockouts
Termination points for wiring conduit and wire glands
12 - Wiring Box Cover
Sheet metal wiring box cover protects power connections
13 - Serial RS-232 Port
9-pin serial connector (female)
14 - EIA-485 Port
Four (4) position screw terminal for EIA-485 bus connections (TS-MPPT-60 model only)
15 - Solar Positive Terminal (yellow)
Power connection for Solar (+)
16 - Common Negative Power Terminals
Two (2) negative terminals for negative system cable termination
17 - Push-button Switch
Manually reset from an error or fault, also used to start/stop a manual equalization.

14 Getting Started
2.5 Optional Accessories
The following accessories are available for purchase separately from your authorized
Morningstar dealer:
TriStar Digital Meter 2 / TriStar Remote Meter 2 (Models: TS-M-2 / TS-
RM-2)
The TriStar Digital Meter mounts directly on the TS-MPPT controller, replacing the wiring box
FRYHU7KH7UL6WDU5HPRWH0HWHUFDQEHÀXVKPRXQWHGLQDZDOORULQWRDVWDQGDUGGXSOH[
gang) electrical box. A2 x 16 character display shows system operating information, error indica-
tions, and self-diagnostic information. Four (4) buttons make navigating the meter menus easy.
For systems where multiple TS-MPPT controllers are networked together, one (1) meter can
display full system information. The TriStar meters connect to the RJ- 11 MeterBusTM port on the
TriStar-MPPT.
Meter Hub (HUB-1)
A Morningstar MeterBusTM network with multiple controllers requires a Meter Hub for electri-
cal isolation. The HUB-1 allows communication between MeterBusTM compatible Morningstar
products, including the TriStar MPPT 150V controller. DIN rail compatible. See section 5.2 for
more details.
Relay Driver (RD-1)
The Relay DriverTM accessory enables the TriStar MPPT 150V to control external devices. Four
UHOD\FRQWUROSRUWVFDQEHFRQ¿JXUHGLQYDULRXVFRPELQDWLRQVWRSHUIRUPWKHIROORZLQJWDVNV
•JHQHUDWRUFRQWURODQGZLUHFRQ¿JXUDWLRQV
• 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 in-
quire with your local Morningstar dealer.
EIA-485 / RS-232 Communications Adapter (RSC-1)
Connect one or more TriStar MPPT 150V controllers to a PC or to other serial devices using the
RSC-1 EIA-485 adapter. The adapter converts an RS-232 serial interface to EIA-485 compliant
signals. An LED shows network activity and errors. DIN rail compatible.

16 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
LQVWDOOHGLQDYHQWLODWHGHQFORVXUHZLWKVXI¿FLHQWDLUÀRZ1HYHULQVWDOOWKH7UL6WDU03379LQ
a sealed enclosure. The controller may be mounted in an enclosure with sealed batteries, but
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the TriStar MPPT 150V circuits.
Multiple TriStars can be installed in parallel on the same battery bank to achieve higher charging
current. Additional parallel controllers can also be added in the future. Each TriStar MPPT 150V
must have its own solar array.
WARNING: Installation must conform to all requirements of the US National Electrical
Code and the Canadian Electrical Code.
AVERTISSEMENT: Installation doit être conforme à toutes les requirments US
National Electrical Code et Code Canadien d’Electricité.
!CAUTION: Equipment Damage or Risk of Explosion
1HYHULQVWDOOWKH7UL6WDU03379LQDQHQFORVXUHZLWKYHQWHGÀRRGHG
EDWWHULHV%DWWHU\IXPHVDUHÀDPPDEOHDQGZLOOFRUURGHDQGGHVWUR\WKH
TriStar MPPT 150V circuits.
!CAUTION: Equipment Damage
:KHQLQVWDOOLQJWKH7UL6WDU03379LQDQHQFORVXUHHQVXUHVXI¿FLHQW
ventilation. Installation in a sealed enclosure will lead to over-heating and
a decreased product lifetime.
PRUDENCE : Endommagement de l’équipement ou risque
d’explosion
N’installez jamais le TriStar MPPT 150V dans une enceinte avec des
batteries à évent/à électrolyte liquide. Les vapeurs des batteries sont
LQÀDPPDEOHVHWFRUURGHURQWHWGpWUXLURQWOHVFLUFXLWVGX7UL6WDU0337
150V.
PRUDENCE : Endommagement de l’équipement
$VVXUH]XQHYHQWLODWLRQVXI¿VDQWHHQFDVG¶LQVWDOODWLRQGX7UL6WDU0337
150V 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. 5HDGDOOLQVWUXFWLRQV¿UVW before beginning installation.
The installation instructions are for installation of a negative grounded system. National Electrical
Code (NEC) requirements are noted on occasion for convenience, however the installer should
have a complete understanding of NEC and UL requirements for photovoltaic installations.
!
!
Installation3.0

18 Installation
3.2 Controller Installation
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 150V power connections.
!
PRUDENCE : Risque de décharge électrique
Déconnectez toutes les sources d’alimentation du contrôleur avant d’enlever le couvercle
du boîtier de câblage. Ne retirez jamais le couvercle en présence de tension sur une des
connexions d’alimentation du TriStar MPPT.
Use a #2 Phillips screw driver to remove the four (4) screws that secure the wiring box cover as
VKRZQLQ¿JXUHEHORZ
Figure 3-1. Remove the wiring box cover.
If a TriStar Digital Meter 2 display is installed, be sure to disconnect the RJ-11 cable.

20 Installation
Step 3 - Mount to a Vertical Surface
!CAUTION: Risk of Burns
Install the TriStar MPPT 150V in a location that prevents casual contact. The
TriStar MPPT 150V heatsink can become very hot during operation.
M6 Screw
Mounting Hanger
Figure 3-2. Attaching the mounting hanger
1. Attach the mounting hanger to the bottom of the TriStar MPPT 150V with the M6 screw pro-
YLGHGDVVKRZQLQ¿JXUH
2. Place the TriStar MPPT 150V on a vertical surface protected from direct sun, high tempera-
tures, and water. The TriStar MPPT 150V requires at least 6” (150 mm) of clearance above
DQGEHORZDQGDWOHDVW´PPRQHDFKVLGHIRUSURSHUDLUÀRZDVVKRZQLQ¿JXUH
below.
AT LEAST
6” (150 mm)
COOL AIR
WARM AIR
AT LEAST
6” (150 mm)
AT LEAST
1” (25 mm)
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22 Installation
Switches 4, 5, & 6: Battery Charging Settings
It is important to select the battery type that matches the system battery to ensure proper charg-
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FKRRVHDVHWWLQJWKDWEHVW¿WVWKHUHFRPPHQGHGFKDUJLQJSUR¿OH
Settings
Switches
4 - 5 - 6
Battery
Type Absorp. Stage
(Volts)
Float
Stage
(Volts)
Equalize
Stage
(Volts)
Equalize
Interval
(Days)
off-off-off 1 - Gel 14.00 13.70
off-off-on 2 - Sealed* 14.15 13.70 14.40 28
off-on-off 3 - Sealed* 14.30 13.70 14.60 28
off-on-on 4 - AGM/Flooded 14.40 13.70 15.10 28
on-off-off 5 - Flooded 14.60 13.50 15.30 28
on-off-on 6 - Flooded 14.70 13.50 15.40 28
on-on-off 7 - L-16 15.40 13.40 16.00 14
on-on-on 8 - Custom Custom Custom Custom Custom
* “Sealed” battery type includes gel and AGM batteries
All settings are for 12 Volt nominal systems. Multiply the charge voltage settings by 2 for 24 Volt
systems or by 4 for 48 Volt systems. A description of each setting is provided below. See sec-
tion 4.3 for full details on battery charging and a description of each of the settings in the battery
charging table.
Battery Type7KHPRVWFRPPRQEDWWHU\W\SHDVVRFLDWHGZLWKWKHVSHFL¿HGFKDUJLQJVHWWLQJV
Absorption Stage - This stage limits input current so that theAbsorption voltage is maintained.
As the battery becomes more charged, the charging current continues to taper down until the
battery is fully charged.
Float Stage - When the battery is fully charged, the charging voltage will be reduced to the Float
voltage setting.
Equalize Stage - During an equalization cycle, the charging voltage will be held constant at the
VSHFL¿HGYROWDJHVHWWLQJ
Equalize Interval - The number of days between equalization charges when the controller is con-
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Switch 7: Battery Equalization
Choose between manual and automatic battery equalization charging. In the manual equaliza-
tion setting, an equalization will only occur when manually started with the push-button or when
requested from the equalize menu on the TriStar meter. Automatic equalization will occur accord-
LQJWRWKHEDWWHU\SURJUDPVSHFL¿HGE\VHWWLQJVVZLWFKHVLQWKHSUHYLRXVVWHS

24 Installation
Step 5 - Remote Temperature Sensor
The included Remote Temperature Sensor (RTS) is recommended for effective temperature com-
pensated charging. Connect the RTS to the 2-position terminal located between the battery (+)
WHUPLQDOOXJDQGWKH/('VWDFNVHH¿JXUH7KH576LVVXSSOLHGZLWKIWPRI$:*
(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. Tighten the
connector screws to 5 in-lb (0.56 Nm) of torque. Separate installation instructions are provided
inside the RTS bag.
WARNING: Risk of Fire.
If no Remote Temperature Sensor (RTS) is connected, use the TriStar MPPT 150V
within 3m (10 ft) of the batteries. Internal Temperature Compensation will be used if
the RTS is not connected. Use of the RTS is strongly recommended.
AVERTISSEMENT : Risque d’incendie.
Si non Capteur de température distant (RTS) est connecté, utilisez le MPPT ProStar
moins de 3m (10 pi) de les batteries. Compensation de la température interne sera
utilisée si la RTS n’est pas connecté. Utilisation de la RTS est fortement recommandé.
!CAUTION:
The TriStar MPPT 150V will not temperature compensate charging parameters if
the RTS is not used.
!CAUTION: Equipment Damage
Never place the temperature sensor inside a battery cell. Both the RTS and the
battery will be damaged.
NOTE:
The RTS cable may be shortened if the full length is not needed. Be sure to
reinstall the ferrite choke on the end of the RTS if a length of cable is removed.
This choke ensures compliance with electromagnetic emissions standards.
!PRUDENCE:
Le TriStar MPPT 150V ne compense pas la température des paramètres de
charges si le RTS n’est pas utilisé.
!PRUDENCE : Endommagement de l’équipement
Ne placez jamais la sonde de température dans un élément de batterie. Le RTS
et la batterie seraient endommagés.
REMARQUE :
Le câble de RTS peut être raccourci si la totalité de la longueur n’est pas
nécessaire. Assurez-vous de réinstaller la bobine en ferrite sur l’extrémité du
RTS si une longueur de câble est enlevée. Cette bobine assure la conformité
avec les normes d’émissions électromagnétiques.

26 Installation
Step 7 - Battery Voltage Sense
The voltage at the battery connection on the TriStar MPPT 150V may differ slightly from the volt-
age directly at the battery bank terminals due to connection and cable resistance. The Battery
Voltage Sense connection enables the TriStar MPPT 150V to measure the battery terminal volt-
age precisely with small gauge wires that carry very little current, and thus have no voltage drop.
Both battery voltage sense wires are connected to the TriStar at the 2-position terminal located
EHWZHHQWKHSXVKEXWWRQDQGWKHSRVLWLYHWHUPLQDOOXJVHH¿JXUH
A battery voltage sense connection is not required to operate your TriStar MPPT 150V controller,
but it is recommended for best performance. If a TriStar meter will be added to the controller, the
battery voltage sense will ensure that the voltage and diagnostic displays are very accurate.
The voltage sense wires should be cut to length as required to connect the battery to the voltage
sense terminal. The wire size can range from 16 to 24 AWG (1.0 to 0.25 mm2). A twisted pair
cable is recommended but not required. Use UL rated 300 Volt conductors. The voltage sense
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.
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RTS (if installed) are both present and detected by the controller. MSViewTM PC software can
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Step 8 - Network Connections
Network connections allow the TriStar MPPT 150V to communicate with other controller or com-
puters. 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.
WARNING: Shock Hazard
Only use 300 Volt UL rated communication cable.
AVERTISSEMENT : Risque de décharge électrique
N’acheminez jamais les câbles réseau dans le même conduit que les
conducteurs d’alimentation.

28 Installation
RS-232 Connection
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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.
Ethernet Connection
The RJ-45 Ethernet jack features two (2) indicator LEDs for connection status and network traf-
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through conduit before crimping on the RJ-45 connectors. If using pre-assembled cables, take
care not to damage the plugs when the cables are pulled through conduit.
MeterBusTM Connection
MeterBusTM networks use standard 4-wire or 6-wire RJ-11 telephone cables. If possible, pull the
telephone cable through conduit before crimping on the RJ-11 connectors. If using pre-assem-
bled cables, take care not to damage the plugs when the cables are pulled through conduit.
Y-cable Connections for EMC-1 Use
TS-MPPT-30 and TS-MPPT-45 units can be Ethernet connected using the EMC-1 accessory and
an EMC-1 provided Y-cable. These models need to be connected to the EMC-1 with the Y-cable
(DB-9 serial and RJ-11 plugs at the TS-MPPT) and an RJ-11 plug at the EMC-1.

30 Installation
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.
The NEC requires solar and battery fuses or DC breakers to be installed in the system. These
protection devices are external to the TriStar MPPT 150V controller, and must be a maximum of 45
amps for the TS-MPPT-30, 70 amps for the TS-MPPT 45 and 90 amps for the TS-MPPT-60.
Maximum battery short-circuit current rating must be less than the interrupt current rating of the
battery over-current protection device referenced above.
WARNING: Breakers and fuses may require lower ratings than referenced above, so as
not to exceed any specific wire ampacity.
AVERTISSEMENT: Disjoncteurs et fusibles peuvent exiger des cotes inférieures que
mentionnés ci-dessus de manière à ne pas pour dépasser n’importe quel fils
particulier admissible.
Connect the Power Wires
WARNING: Shock Hazard
The solar PV array can produce open-circuit voltages in excess of 150 Vdc when
in sunlight. Verify that the solar input breaker or disconnect has been opened
(disconnected) before installing the system wires.
AVERTISSEMENT : Risque de décharge électrique
Le réseau PV solaire peut produire des tensions de circuit ouvert supérieures à 150
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solaire a été ouvert (déconnexion) avant d’installer les câbles du système.

32 Installation
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 150V. 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.
Activez le coupe-circuit/interrupteur de réseau solaire et mesure la tension sur
les câbles ouverts AVANT la connexion au TriStar MPPT 150V. Déconnectez le
coupe-circuit/interrupteur solaire avant le câblage sur le contrôleur.
6. Connect the Solar + (positive) wire to the Solar + terminal on the TriStar MPPT 150V. The
Solar + terminal has a yellow cover.
7. Connect the Solar - (negative) wire to one of the Common Negative terminals on the
TriStar MPPT 150V.
Torque all four (4) power terminals to 50 in-lbs (5.65 Nm)
Power-up
WARNING: Risk of Damage
Connecting the solar array to the battery terminal will permanently damage the
TriStar MPPT 150V.
WARNING: Risk of Damage
Connecting the solar array or battery connection with reverse polarity will
permanently damage the TriStar MPPT 150V.
AVERTISSEMENT : Risque d’endommagement
La connexion du réseau solaire sur la borne de la batterie endommagera le
TriStar MPPT 150V de façon permanente.
AVERTISSEMENT : Risque d’endommagement
La connexion du réseau solaire ou la connexion de la batterie avec une polarité
inversée endommagera le TriStar MPPT 150V de façon permanente.
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start-up. (LEDs blink Green - Yellow - Red in one cycle)
• Note that a battery must be connected to the TriStar MPPT 150V to start and operate the
controller. The controller will not operate only from solar input.
• Turn the solar disconnect on. If the solar array is in full sunlight, the TriStar MPPT 150V
will begin charging. If an optional TriStar Meter is installed, charging current will be report-
ed along with charging state.

34 Operation
Operation4.0
The TriStar MPPT 150V 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 150V as described in this section.
4.1 TrakStarTM MPPT Technology
The TriStar MPPT 150V utilizes Morningstar’s TrakStarTM Maximum Power Point Tracking
(MPPT) technology to extract maximum power from the solar array. The tracking algorithm is fully
automatic and does not require user adjustment. TrakStarTM technology tracks the array maxi-
mum power point as it varies with weather conditions, ensuring that maximum power is harvested
from the array throughout the course of the day.
Current Boost
Under most conditions, TrakStarTM MPPT technology will “boost” the solar charge current. For
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Rest assured that the power into the TriStar MPPT 150V is the same as the power out of the
TriStar MPPT 150V. Since power is the product of voltage and current (Volts x Amps), the follow-
ing is true*:
(1) Power Into the TriStar MPPT 150V = Power Out of theTriStar MPPT 150V
(2) Volts In x Amps In = Volts Out x Amps Out
* assuming 100% efficiency. Losses in wiring and conversion exist.
If the solar module’s maximum power voltage (Vmp) is greater than the battery voltage, it follows
that the battery current must be proportionally greater than the solar input current so that input
and output power are balanced. The greater the difference between the Vmp and battery voltage,
the greater the current boost. Current boost can be substantial in systems where the solar array
is of a higher nominal voltage than the battery as described in the next section.
High Voltage Strings and Grid-Tie Modules
$QRWKHUEHQH¿WRI7UDN6WDUTM MPPT technology is the ability to charge batteries with solar arrays
of higher nominal voltages. For example, a 12 volt battery bank may be charged with a 12, 24,
36, or 48 volt nominal off-grid solar array. Grid-tie solar modules may also be used as long as
the solar array open circuit voltage (Voc) rating will not exceed the TriStar MPPT 150V 150 Volt
maximum input voltage rating at worst-case (coldest) module temperature. The solar module
documentation should provide Voc vs. temperature data.
Higher solar input voltage results in lower solar input current for a given input power. High voltage
solar input strings allow for smaller gauge solar wiring. This is especially helpful and economical
for systems with long wiring runs between the controller and the solar array.

36 Operation
4.2 Battery Charging Information
4-Stage Charging
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battery charging. Figure 4-2 shows the sequence of the stages.
NIGHT NIGHT
BULK
CHARGE
ABSORPTION
FLOAT
EQUALIZE
VOLTAGE
TIME
Figure 4-2. TriStar MPPT 150V Charging Algorithm
Bulk Charge Stage
In Bulk charging stage, the battery is not at 100% state of charge and battery voltage has not yet
charged to the Absorption voltage set-point. The controller will deliver 100% of available solar
power to recharge the battery.
Absorption Stage
When the battery has recharged to the Absorption voltage set-point, constant-voltage regulation
is used to maintain battery voltage at the Absorption set-point. This prevents heating and exces-
sive battery gasing. The battery is allowed to come to full state of charge at the Absorption volt-
age set-point. The green SOC LED will blink once per second duringAbsorption charging.
The battery must remain in the Absorption charging stage for a cumulative 120 - 150 minutes,
depending on battery type, before transition to the Float stage will occur. However, Absorption
time will be extended by 30 minutes if the battery discharges below 12.5 Volts (25 Volts @24 V,
50 Volts @48 V) the previous night.
The Absorption set-point is temperature compensated if the RTS is connected; otherwise,
voltages set-points are based on the reference of 25ºC.
.

38 Operation
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voltages, and complete the chemical reactions. Equalize charging raises the battery voltage
above the standard absorption voltage so that the electrolyte gases. The green SOC LED will
blink rapidly two (2) times per second during equalization charging.
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LVGH¿QHGDVWLPHVSHQWDWWKHHTXDOL]H
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will terminate after an additional 60 minutes to avoid over gasing or heating the battery. If the
battery requires more time in equalization, an equalize can be requested using the TriStar Meter
or push-button to continue for one or more additional equalization cycles.
The Equalize set-point is temperature compensated if the RTS is connected; otherwise, voltages
set-points are based on the reference of 25ºC.
.
When to Equalize
The ideal frequency of equalizations depends on the battery type (lead-calcium, lead-antimony,
etc.), the depth of discharging, battery age, temperature, and other factors. One very broad
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Some batteries, such as the L-16 group, will need more frequent equalizations.
The difference between the highest cell and lowest cell in a battery can also indicate the need
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Why Equalize?
Routine equalization cycles are often vital to the performance and life of a battery - particularly
in a solar system. During battery discharge, sulfuric acid is consumed and soft lead sulfate
crystals form on the plates. If the battery remains in a partially discharged condition, the soft
crystals will turn into hard crystals over time. This process, called “lead sulfation,” causes the
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Sulfation from chronic undercharging of the battery is the leading cause of battery failures in
solar charging systems. In addition to reducing the battery capacity, sulfate build-up is the
most common cause of buckling plates and cracked grids. Deep cycle batteries are particularly
susceptible to lead sulfation.
Normal charging of the battery can convert the sulfate back to the soft active material if the
battery is fully recharged. However, a solar charged battery is seldom completely recharged, so
the soft lead sulfate crystals harden over a period of time. Only a long controlled overcharge, or
equalization, at a higher voltage can reverse the hardening of sulfate crystals.