Morningstar TRISTAR TS-MPPT-60 User manual

Installation and Operation Manual
Solar System Controller
8 Pheasant Run
Newtown, PA 18940 USA
email: [e-mail]
www.morningstarcorp.com
Solar Battery Charger
with
TrakStarTM Maximum Power Point Tracking Technology
Models
TS-MPPT-60
TS-MPPT-45
MAXIMUM POWER POINT TRACKING
TRISTAR MPPT
TM

Dimensions in Inches [Millimeters]

Contents
1.0 Important Safety Information 4
2.0 Getting Started 8
2.1 Overview 8
2.2 Versions and Ratings 8
2.3 Features 9
2.4 Regulatory Information 11
2.5 Optional Accessories 12
3.0 Installation 13
3.1 General Information 13
3.2 Controller Installation 15
4.0 Operation 30
4.1 TrakStarTM MPPT Technology 30
4.2 Battery Charging Information 32
4.3 Push button 40
4.4 LED Indications 41
4.5 Protections, Faults & Alarms 43
4.6 Inspection and Maintenance 46
5.0 Networking and Communication 47
5.1 Introduction 47
5.2 Morningstar MeterBusTM 48
5.3 Serial RS-232 49
5.4 EIA-485 (formerly RS-485) 51
5.5 Ethernet 52
6.0 Troubleshooting 55
7.0 Warranty 57
8.0 Specifications 58

4Important Safety Information
Save These Instructions
This manual contains important safety, installation and operating instructions for the
TriStar MPPT solar controller.
The following symbols are used throughout this manual to indicate potentially dangerous condi-
tions 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. Do not disassemble or at-
tempt to repair the controller.
• Disconnect all sources of power to the controller before installing or adjusting the
TriStar MPPT.
• There are no fuses or disconnects inside the TriStar MPPT. Do not attempt to repair.
• Install external fuses/breakers as required.
Informations de sécurité
• Lisez toutes les instructions et les avertissements figurant dans le manuel avant de com-
mencer l’installation.
• Le TriStar MPPT 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 TriStar MPPT.
• Le TriStar MPPT ne contient aucun fusible ou interrupteur. Ne tentez pas de réparer.
• Installez des fusibles/coupe-circuits externes selon le besoin.
1.0 Important Safety Information

5TriStar MPPT 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 TriStar MPPT indoors. Prevent exposure to the elements and do not allow wa-
ter to enter the controller.
• 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 identified by the sym-
bol below.
Ground Symbol
• This charge controller is to be connected to DC circuits only. These DC connections are
identified by the symbol below.
Direct Current Symbol

6Important Safety Information
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 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.
• 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 identifiée
par le symbole ci-dessous.
• 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 doit être installé par un technicien qualifié conformément aux règle-
mentations 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 (dans le compartiment de câblage), un
moyen permanent et fiable de mise à la terre doit être fourni. La fixation de la mise à la terre doit
être fixée contre tout desserrage accidentel.
Les ouvertures d’entrée au compartiment de câblage du TriStar MPPT doivent être protégées
avec un conduit ou une bague.

7TriStar MPPT Operator’s Manual
About this Manual
This manual provides detailed installation and usage instructions for the TriStar MPPT controller.
Only qualified electricians and technicians who are familiar with solar system design and wiring
practices should install the TriStar MPPT. The usage information in this manual is intended for
the system owner/operator.

8TriStar MPPT Operator’s Manual
Getting Started2.0
2.1 Overview
Thank you for selecting the TriStar MPPT solar charge controller with TrakStarTM MPPT Technol-
ogy. The TriStar MPPT (TS-MPPT) 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.
The TriStar MPPT battery charging process has been optimized for long battery life and im-
proved 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 can provide for your PV
system.
2.2 Versions and Ratings
There are two versions of TriStar MPPT controllers.
TriStar-MPPT-45
• maximum 45 amps continuous battery current
• 12, 24, 36, 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, 36, and 48 Volt dc systems
• maximum 150 Volt dc solar input voltage
• RS-232, EIA-485, MeterBusTM, and Ethernet communication ports
To comply with the National Electric Code (NEC), the current rating of the controller must be
equal to or greater than 125% of the solar array’s short circuit current output (Isc). Therefore, the
maximum allowable solar array input to the TriStar MPPT controller for compliance with the NEC
is:
TS-MPPT-45: 36 amps Isc*
TS-MPPT-60: 48 amps Isc*
*Solar array Isc @ STC

9TriStar MPPT Operator’s Manual
2.3 Features
The features of the TriStar MPPT are shown in Figure 2-1 below. An explanation of each feature
is provided.
Figure 2-1. TriStar MPPT features

10 Getting Started
1 - Heatsink
Aluminum heatsink to dissipate controller heat
2 - Mounting Hanger
Keyhole slot for mounting
3 - Settings Switches
Eight (8) settings switches to configure operation of the TriStar MPPT
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.

11TriStar MPPT Operator’s Manual
2.4 Regulatory Information
NOTE:
This section contains important information for safety and
regulatory requirements.
The TriStar MPPT controller should be installed by a qualified technician according to the electri-
cal rules of the country in which the product will be installed.
TriStar MPPT controllers comply with the following EMC standards:
• Immunity: EN61000-6-2:1999
• Emissions: EN55022:1994 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 fixed wiring.
Using the TriStar MPPT grounding terminal (in the wiring compartment), a permanent and reli-
able means for grounding shall be provided. The clamping of the earthing shall be secured
against accidental loosening.
The entry openings to the TriStar MPPT 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 modifications not expressly approved by Morningstar for compliance could void the user’s authority to
operate the equipment.
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 resi-
dential 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:
• Reorient or relocate 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.

12 Getting Started
2.5 Optional Accessories
The following accessories are available for purchase separately from your authorized Morning-
star 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
cover. The TriStar Remote Meter can be flush mounted in a wall or into a standard duplex (2-
gang) electrical box. A 2 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 electrical
isolation. The HUB-1 allows communication between MeterBusTM compatible Morningstar prod-
ucts, including the TriStar MPPT controller. DIN rail compatible. See section 5.2 for more details.
Relay Driver (RD-1)
The Relay DriverTM accessory enables the TriStar MPPT 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.com or in-
quire with your local Morningstar dealer.
EIA-485 / RS-232 Communications Adapter (RSC-1)
Connect one or more TriStar MPPT 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.

13 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 in-
stalled in a ventilated enclosure with sufficient air flow. Never install the TriStar MPPT in a sealed
enclosure. The controller may be mounted in an enclosure with sealed batteries, but never
with vented/flooded batteries. Battery fumes from vented batteries will corrode and destroy the
TriStar MPPT 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 must
have its own solar array.
!CAUTION: Equipment Damage or Risk of Explosion
Never install the TriStar MPPT in an enclosure with vented/flooded batteries. Battery
fumes are flammable and will corrode and destroy the TriStar MPPT circuits.
!CAUTION: Equipment Damage
When installing the TriStar MPPT in an enclosure, ensure sufficient 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 dans une enceinte avec des batteries à évent/à
électrolyte liquide. Les vapeurs des batteries sont inflammables et corroderont et
détruiront les circuits du TriStar MPPT.
!PRUDENCE : Endommagement de l’équipement
Assurez une ventilation suffisante en cas d’installation du TriStar MPPT 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 straightforward, 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. 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

14 Installation
Recommended Tools:
• Wire strippers
• Wire cutters
• #2 & #0 Phillips screwdriver
• slotted screwdrivers
• Pliers
• Drill
• 3/32” (2.5 mm) drill bit
• Level
• hack saw (cutting conduit)

15TriStar MPPT Operator’s Manual
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 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
shown in figure 3-1 below.
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.

16 Installation
Step 2 - Remove the knockouts
Knockouts are provided for routing cables through conduit or wire glands. Table 3-1 below pro-
vides the knockout sizes and quantity on the TriStar MPPT wiring box. Knockout locations and
dimensions are on the inside front cover.
Quantity Trade Size Hole Dimension
8 1/2” or M20 7/8” (22.2 mm)
6 1 “ 1 - 23/64 “ (34.5 mm)
4 1 - 1/4 “ 1 - 23/32 “ (43.7 mm)
Table 3-1. Knockout sizes
!CAUTION: Shock Hazard
Always use bushings, connectors, clamp connectors, or wire glands in the knockout openings to
protect wiring from sharp edges.
!PRUDENCE : Risque de décharge électrique
Utilisez toujours des bagues, des connecteurs, des raccordements à collets ou des fouloirs dans
les ouvertures afin de protéger le câblage des bords coupants.
!CAUTION: Shock Hazard
Never route network cables in the same conduit as the power conductors.
!PRUDENCE : Risque de décharge électrique
N’acheminez jamais les câbles réseau dans le même conduit que les conducteurs
d’alimentation.
Plan the routing of each conductor that will connect to the TriStar MPPT before removing any
knockouts. The 1/2” (M20) knockouts are ideal for routing network cables, which must be placed
in separate conduit.

17TriStar MPPT Operator’s Manual
Step 3 - Mount to a Vertical Surface
Figure 3-2. Attaching the mounting hanger
1. Attach the mounting hanger to the bottom of the TriStar MPPT with the M6 screw provided as
shown in figure 3-2.
2. Place the TriStar MPPT on a vertical surface protected from direct sun, high temperatures,
and water. The TriStar MPPT requires at least 6” (150 mm) of clearance above and below
and at least 1” (25 mm) on each side for proper air flow as shown in figure 3-3 below.
Figure 3-3. 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.
Leave a 1/4” (6 mm) gap between the mounting surface and screw head.

18 Installation
6. Carefully align the keyhole on the TriStar MPPT with the screw head. Slide the TriStar MPPT
down over the keyhole.
7. Check for vertical plumb with a level.
8. Mark two (2) mounting hole locations in the wiring box.
9. Remove the controller and drill 3/32” (2.5 mm) holes at the drill marks.
10.Carefully align the keyhole on the TriStar MPPT with the screw head. Slide the TriStar MPPT
down over the keyhole.
11. The pre-drilled pilot holes should align with the mounting holes in the wiring box. Secure the
controller with two (2) #10 mounting screws.
12.Tighten the keyhole screw.
Step 4 - Adjust Settings Switches
Switch 1: Reserved for Future Use
Settings switch 1 should remain in the “OFF” position.
Mode Switch 1
Solar Charging OFF
future use ON
Switches 2 & 3: System Voltage
Four (4) system voltage configurations are available as shown in the table below:
System Voltage Switch 2 Switch 3
Auto OFF OFF
12 OFF ON
24 ON OFF
48 ON ON
The “auto” setting allows the TriStar MPPT to detect the system voltage automatically on start up.
The test is only performed at start up and the detected system voltage will never change during
operation.
Generally, it is best to choose a specific system voltage. The auto detect feature should only be
used in situations where the system voltage is unknown ahead of time or in systems where the
system voltage may change periodically.

19TriStar MPPT Operator’s Manual
Switches 4, 5, & 6: Battery Charging Settings
It is important to select the battery type that matches the system battery to ensure proper charg-
ing 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 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 - 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.
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
specified voltage setting.
Equalize Interval - The number of days between equalization charges when the controller is con-
figured for automatic equalizations (settings switch 7).
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 pushbutton or when
requested from the equalize menu on the TriStar meter. Automatic equalization will occur accord-
ing to the battery program specified by settings switches 4, 5, & 6 in the previous step.
In both settings (auto and manual), the pushbutton can be used to start and stop battery equal-
ization. If the selected battery charging setting does not have an equalization stage an equaliza-
tion will never occur, even if requested manually.

20 Installation
Equalize Switch 7
manual OFF
automatic ON
Switch 8: Ethernet Security
The Ethernet Security switch enables or disables configuration of the TriStar MPPT settings
through the Ethernet connection. When switch eight is set to disabled, write commands to the
TriStar MPPT custom memory are not allowed. This a safety feature to prevent unintended
changes to custom settings, but it is not a replacement for proper network security.
Configuration via TCP/IP Switch 8
disabled OFF
enabled ON
NOTE:
Adjustment of network settings and custom setpoints is always enabled via the RS-232 and EIA-
485 connections. The Ethernet Security switch only enables/disables remote configuration via
TCP/IP.
!CAUTION: Risk of Tampering
The Ethernet Security settings switch does not block write commands to devices bridged via EIA-
485.
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.
!PRUDENCE : Risque de tentative d’altération
Le contacteur des paramètres de sécurité Ethernet ne bloque pas les commandes d’écriture sur
les dispositifs reliés par EIA-485.