Morningstar Tristar TS-MPPT-60M 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.