Morningstar EMC-1 User manual

www.morningstarcorp.com
EMC-1TM
Ethernet Meterbus Converter
Installation and Operation Manual
DIMENSIONS [inches (millimeters)]
3.37
(
86 )
6.04
( 153 )
2.17
( 55 )
5.51
( 140 )
1.20
( 30 )
4.85
( 123 )
SPECIFICATION SUMMARY
EMC-1
Required Power Source System battery for Morningstar
Device, or AC-DC converter
Required Power Supply
Connection On-board terminals
Input Voltage 8-80 Vdc
Ethernet Speed 10/100Base-T
For the most recent manual revisions, see the
version at: www.morningstarcorp.com

TABLE OF CONTENTS
1.0 General Information........................................... 1
1.1 Overview.............................................................1
1.2 Features..............................................................3
2.0 Installation...........................................................4
2.1 Mounting............................................................4
2.2 Configuration......................................................5
2.3 Connections....................................................... 6
2.3.1 Installing the EMC-1.......................................... 6
2.3.2 TriStar and TriStar MPPT Installation Using a
Y-cable Adaptor................................................... 6
2.4 DIP Switch Set-up..............................................7
2.4.1 Ethernet Writes..................................................7
2.5 Connecting the Power Wires............................ 8
3.0 Operation............................................................ 9
3.1 Start-up..............................................................9
3.2 LED Indicators..................................................10
3.3 EMC-1 Status LEDs..........................................10
3.4 Web Service LEDs........................................... 11
3.5 Ethernet Write LED.........................................11
3.6 Connectivity..................................................... 11
3.6.1 MSView............................................................ 11
3.6.2 LiveView Web Pages........................................12
3.6.3 Connecting to a LAN / WAN...........................13
3.6.4 Connecting to the EMC-1 from a Remote
Location...........................................................14
3.7 Push-button Functions.....................................15
3.7.1 Factory Reset................................................... 15
3.7.2 To Recover from a Failed Firmware
Update............................................................ 15
TABLE OF CONTENTS (Cont.)
4.0 Troubleshooting................................................16
4.1 Faults and Corrections.......................................16
5.0 Warranty..................................................... .18
6.0 Technical Specifications....................................19
7.0 Certifications.....................................................20

1 2
1.0 GENERAL INFORMATION
1.1 Overview
The EMC-1 is a MODBUSTM Ethernet to MeterbusTM
converter that bridges a TCP/IP connection to a
Morningstar charge controller or inverter (Morningstar
Device) not having built-in Ethernet connectivity. The
connected device needs to have a Meterbus (RJ-11)
port.
The EMC-1 acts as an Ethernet gateway that serves
MODBUS IP, local Web pages, and Web Monitoring
Services. Note that the Web Monitoring Service is
not available as of this printing. Ethernet connectivity
allows users to remotely collect information about
their off-grid PV system. Ethernet networks also
include local area networks (LANs) and Internet
communications.
The EMC-1 supports the following communication
capabilities with a Morningstar Device:
• Morningstar LiveViewTM Internet Web monitoring
and Network settings changes;
• Monitoring, logging and custom programming
using Morningstar MSViewTM PC software;
• (Future use) Web Monitoring for data reporting
and 3rd party visibility
The table below lists products supported by the
EMC-1, and includes port and data details. For the
most recent list, see the latest manual version at:
www.morningstarcorp.com
Product Modbus via
RJ-11 RS-232 Port Logs Historical Data
PS-MPPT-25/M Yes No Yes
PS-MPPT-40/M Yes No Yes
SunSaver Duo Yes No No
SunSaver-
MPPT-15L Yes No Yes
SureSine-300
(all models) Yes No No
TS-45* No Yes Yes
TS-60* No Yes Yes
TS-MPPT-30* No Yes Yes
TS-MPPT-45* No Yes Yes
TS-MPPT-60* No Yes Yes
* The EMC-1 included Y-cable is required to draw power from
the RJ-11 port while communicating via the RS-232 port. See
Section 2.3.2.
Table 1-1 Supported Products

4
3
1.2 Features
The features of the EMC-1 are shown in Figure 1-1
below. An explanation of each feature follows.
1 - DIP Switches
DIP 1 enables Ethernet write commands.
DIP 2 enables Web Monitoring Service (future use)
2 - Ethernet port (RJ-45)
Used to connect the EMC-1 to LAN / Internet
3 - Power Input
8-80 Vdc power input
4 - Status LED
Green and red lights indicate unit status
5 - Web Monitoring Service LED
Green and red LEDs indicate Web Service status
6 - Ethernet Write LED
Green light indicates Ethernet write command capability
7 - Meterbus (RJ-11 port)
Used to connect the EMC-1 to Morningstar Device
8 - DIN rail mounts (bottom of unit)
35mm standard size
4
7
5 6
2
3
1
8
Figure 1-1 EMC-1 Features
2.0 INSTALLATION
2.1 Mounting
The EMC-1 can be wall-mounted, surface-mounted or
DIN rail mounted using basic tools:
Flat head screw driver
Philips head screw driver
Drill (if wall or surface mounting)
1/8” drill bit (if wall or surface mounting)
Option 1 - Wall and Surface Mounting:
Step 1
Locate the EMC-1 on a surface that is protected from
direct sun, high temperatures, corrosive fumes, and water.
Do not install in a confined area where battery gases can
accumulate.
Step 2
Before starting the installation, place the EMC-1 on the
surface where it will be mounted and determine where the
wires will enter and exit. Be sure there is sufficient bending
room for the wires and communication cables. If possible,
verify that the mounting screws will not penetrate wires or
other objects located on the opposite side of the surface.
Step 3
Place the EMC-1 on the intended mounting surface, mark
four holes for drilling. Remove the EMC-1 from the
surface, and using a 1/8” bit, drill pilot holes for each of
the four mounting screws, as indicated on the surface.

5 6
Step 4
Place the EMC-1 onto the surface and align the mounting
feet holes with the four pilot holes. Use the included #10
screws to secure the EMC-1 to the surface.
Option 2 - DIN Rail Mounting:
The EMC-1 will also mount to standard 1-3/8” (35mm) DIN
rail.
Step 1
Choose the DIN rail mounting location. It should be
protected from direct sun, high temperatures, corrosive
fumes, and water. Do not install the EMC-1 in a confined
area where battery gases can accumulate.
Step 2
Confirm sufficient space above and below the DIN rail
mounting location for EMC-1 cable connections. Using
screws, secure the DIN rail to the desired surface.
Step 3
The EMC-1 is designed for tool-less installation onto a DIN
rail. There are four hooks on the bottom of the EMC-1
that slide over the upper and lower lips of the DIN rail.
2.2 Configuration
For communication via the EMC-1, the Morningstar
Device’s DIP switches, if applicable, must be set for
MODBUS communication. The SunSaver MPPT,
ProStar MPPT, and the SureSine products need to
have the appropriate DIP switch set for MODBUS
communication. See Section 2.4 for EMC-1 DIP switch
settings.
2.3 Connections
2.3.1 Installing the EMC-1
NOTE: Make COM connections with no power applied
Insert an Ethernet cable (A) into the RJ-45 jack of the
EMC-1. Insert the plug on one end of a six-conductor
RJ-11 cable (B) into the RJ-11 jack on the EMC-1.
Insert the plug on the other end of the RJ-11 cable
into the RJ-11 port of the Morningstar Device. See
the Operation section (3) for details on the start-up
procedure.
Figure 2-1. Connecting the COM cables
2.3.2 TriStar and TriStar MPPT Installation Using a
Y-cable Adaptor
TriStar and TriStar-MPPT controllers must use the
included Y-cable adapter to connect to the EMC-1.
The RS-232 serial and RJ-11 plugs are connected at
the controller, and the other RJ-11 plug at the EMC-1.
A
B
RJ-45
RJ-11
NOTE: Make COM connections
with no power applied

7 8
2.4 DIP Switch Set-Up
Figure 2-2 below shows DIP switch locations and
functions:
Figure 2-2. DIP Switch Functions
2.4.1 Ethernet Writes
With DIP 1 ON, Ethernet writes are enabled, and
custom programs, firmware updates and network
settings can be written to a Morningstar Device.
Though this DIP switch is a safety feature designed
to prevent unintended configuration changes to the
Morningstar Device, DIP 1 is not a replacement for
proper network security.
DIP 1 ON (up)
- Enables Ethernet
Writes
DIP 2 - Future Use
2.5 Connecting the Power Wires
The EMC-1 is powered from an 8-80 Vdc supply, such
as an AC-DC converter or system battery connected
to the power input provided on the EMC-1 unit. See
the Operation section (3) for details on the start-up
procedure. Connect the power wires as indicated in
Figure 2.3 below.
Figure 2-3. Connecting the power wires
NOTE: Although the Morningsta r Device will provide
power to the EMC-1 through the Meterbus port, it may
not be sufficient under all operating conditions. The
8-80V power supply is required as a constant, reliable
power source.
OK!
5A fuse and holder -
4 in. from (-) battery
post
NOTE: The EMC-1 will start up with
an RJ-11 connection to a powered
Morningstar Device, or with direct
power to the EMC-1

9 10
3.0 OPERATION
3.1 Start-up
After the EMC-1 has been installed, as described in
Section 2.3.1, the unit is started by connecting the
power supply, as described in section 2.5.
On start-up, the status LED will flash green once, and
then all three LEDs (green, green, green) will light
simultaneously for three seconds. Next, the EMC-1
will automatically begin searching for valid Morningstar
Devices. If equipped, the Morningstar Device must have
its MODBUS DIP switch enabled for the connection to be
made.
EMC-1 START-UP INDICATION
Status LED flash green
LEDs ON for 3 secs green + green + green
With the EMC-1 powered, and the RJ-45 cable
connected, LEDs will light as indicated in the table
below.
ETHERNET JACK INDICATIONS
Condition Green LED Yellow
LED
Network Connection OK ON OFF
Network Activity ON Blinking
Error OFF ON
3.2 LED Indicators
There are three EMC-1 LED indicators - see Figure 3-1
below - that will show all statuses of the EMC-1 - left
to right: Status LED (green / red); Web Service LED
(green / red); Ethernet write enable LED (green).
Figure 3-1. LED Indicators
3.3 EMC-1 Status LEDs (green and red)
Flashing green: 1 every sec Searching for Morningstar
Device
Solid green Morningstar Device found,
communicating
Solid red No valid Morningstar Devices
found
Flashing red - green:
1 every sec
Morningstar Device found,
unkown device ID - update
EMC-1 firmware
Flashing green:
3 every sec
Firmware upgrade or downgrade
in progress. Power should not
be removed while in this state.
Flashing red: 1 every 2 sec Internal fault condition
EMC-1
status Web
Service
status
Ethernet
write
status

11 12
3.4 (Future Use) Web Service LEDs (green and
red)
Web Service OFF (DIP 2 Off) Broadcasts disabled
Web Service ON (DIP 2 On) Broadcasts enabled
Flashing green - 1 every
2 secs
Searching for server /
establishing connection
Solid green Connection made / broadcasting
Solid red Cannot connect to server
Flashing red TBD
Flashing red - green:
1 every 2 sec
Invalid log-in credentials*
(connected to server)
* Log-in and/or server registration error
3.5 Ethernet Write LED (green)
DIP 1 OFF (green OFF) Ethernet writes disabled
DIP 1 ON (green ON) Ethernet writes enabled
3.6 Connectivity
3.6.1 MSView
MSView is a Morningstar software utility that allows
real-time system data interface with a PC, the
capability to custom program charging parameters,
and data logging. MSView is available for download,
at no charge: www.morningstarcorp.com/msview/
For complete connection details, see the Product
Connectivity Manual, available on our website:
www.morningstarcorp.com/wp-content/up-
loads/2014/02/
The Device tab in MSView can be used to, “Search
for Connected Devices”. The search screen will show
the Morningstar Device, its 8-digit serial no. and the
common IP address of the EMC-1 / Morningstar Device.
The IP address can then be used to view Web pages as
described in Section 3.6.2 below. The unit’s default IP
address is 192.168.1.253.
3.6.2 LiveView Web Pages
Using a Web browser, the EMC-1 allows access to a
Morningstar Device’s LiveView Web pages via two
methods:
1) Enter the Morningstar Device’s IP address into the
Address bar e.g. http://192.168.1.186.
2) Enter a Morningstar Device’s NetBIOS name
[product abbreviation + 8-digit serial no.] into the
Address bar e.g. http://ssmppt15320850
Product NetBIOS Abbreviations:
TriStar MPPT tsmppt
ProStar MPPT psmppt
SunSaver MPPT ssmppt
TriStar PWM ts
SunSaver Duo ssduo
SureSine suresine
NOTE: Many networks are DHCP-enabled, and the IP address
assignment will change after some period of time. The
NetBIOS address is a static Morningstar Device identifier, and
will always point to the Morningstar Device.

13 14
After connection to the LiveView server, the following
Web pages are available for viewing:
LiveView
This is the default Web Page, which displays basic
real-time system data, faults and alarms.
Network
This Web Page shows the Morningstar Device’s current
Network settings, and allows the option of changing
COM settings, and port forwarding:
DHCP Primary DNS
IP Address Modbus IP Port 502
Subnet Mask Default Device (MODBUS) ID
Gateway HTTP port 80
Data Log
This Web Page displays the current day, and a certain
period of detailed historical system information,
depending on the number of variables set for logging.
System
The System Web Page is used to update EMC-1
firmware. Connected device firmware cannot be
updated through the System Web Page. The System
Web page also shows specific EMC-1 diagnostic
information.
3.6.3 Connecting to a LAN / WAN
After installing MSView on a PC on a local network,
and with COM and power connections made, as
described in Section 2.3, 2.4, a DHCP enabled router
will a utomatically assign an IP address and network
settings to the EMC-1. The Morningstar Device will also
be read for specific device information before connection
is made. After the original assignment, Network settings
can be changed as desired using the LiveView Network
Web Page.
For complete connection and addressing information, see
Appendix I of the Product Connectivity Manual :
www.morningstarcorp.com/wp-content/up-
loads/2014/02/
ADVANCED TOPIC:
3.6.4 Connecting to the EMC-1 from a Remote
Location (outside of the LAN) via the
Internet / WAN
Basic Procedure:
1. Verify that the Morningstar Device is correctly
connected by accessing it via a Web browser (see
Section 3.6.2). Navigate to the Network Page.
2. In another browser window, enter the network
router default gateway IP address (probably
192.168.1.1, but see Appendix I, Section II of Product
Connectivity Manual - link below).
3. Login to the network router, and choose a static IP
address outside of the listed dynamic range.
4. Return to the LiveView Network Page window,
change the selection to, “Use Static IP Address”,
enter the IP address chosen in the previous step,
re-enter the remaining network settings listed in the
box, including port 502, to direct incoming Internet
requests to the Morningstar Device, and port 80 to
view Morningstar Device Web pages on any Internet
connected PC, then click the “Save” button.
5. To maintain a recognizable public IP address, set
up a Dynamic DNS service, or verify your router’s
Dynamic DNS capabiltiy.

15 16
The Product Connectivity Manual describes all aspects
of connectivity and programming:
www.morningstarcorp.com/wp-content/
uploads/2014/02/
See Appendix 1, Section 3 for full details.
3.7 Push-button Functions
3.7.1 Factory Reset
The EMC-1’s communication settings can be restored
to the factory default conditions. The following values
will be reset:
• TCP / IP settings
• Stored non-volatile product data
To Perform a Factory Reset:
1) With the EMC-1 powered ON, press and hold the
push-button until the status LED (left) starts to flash
R-G, R-G....
2) Release the push-button.
3) The EMC-1 will reboot with the factory default
settings.
3.7.2 To Recover from a Failed Firmware Update
1) With the EMC-1 powered OFF, press and hold the
push-button.
2) Re-apply power, and the green status LED will start
flashing three times every second. Release the push-
button after the flashing begins.
3) The recovery down-grade is in progress, and when
complete, the EMC-1 will serve the System Web
Page, and allow the user to attempt to re-load newer
firmware.
4.0 TROUBLESHOOTING
4.1 Faults and Corrections
The following table 4.1 shows the main EMC-1
error conditions:
Solid red No valid Morningstar Devices
found
Flashing red / green -
1 every sec
Morningstar Device found,
unknown device ID
Flashing red - 1 every 2 sec Internal fault condition
Table 4.1. Error Conditions
Problem:
No valid Morningstar Devices found.
Solution:
Use an RJ-11 cable to connect Morningstar Device to
EMC-1.
Problem:
Morningstar Device found, unknown device ID
Solution:
Update EMC-1 firmware using System Web Page -
see Section 3.6.1.
Problem:
Internal fault condition
Solution:
Contact Morningstar dealer for assistance