Morningstar TriStar TS-45 Installation, Operation And Maintenance Manual Download Page 1

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Solar Charging System Controller

Installation, Operation and

Maintenance Manual

MAXIMUM POWER POINT TRACKING

.....

Solar Battery Charging

. . . . .

Load Control

. . . . .

D i v e r s i o n C o n t r o l

For the most recent manual revisions, see the version at:

www.morningstarcorp.com

MODELS

TS-45
TS-60

TS-60M

www.morningstarcorp.com

Summary of Contents for TriStar TS-45

Page 1: ...peration and Maintenance Manual MAXIMUM POWER POINT TRACKING Solar Battery Charging Load Control Diversion Control For the most recent manual revisions see the version at www morningstarcorp com MODEL...

Page 2: ...sh Installation 26 3 0 Operation 27 3 1 Operator s Tasks 27 3 2 Push button 27 3 3 LED Indications 28 3 4 Protections and Fault Recovery 29 3 5 Data Logging 32 3 6 Inspection and Maintenance 32 4 0 So...

Page 3: ...ix 3 LED Indications 70 12 0 Certifications 73 co nt i nued IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety installation operating and mantenance instructio...

Page 4: ...xposure to the elements and do not allow water to enter the controller Install the TriStar PWM in a location that prevents casual contact The TriStar PWM heatsink can become very hot during operation...

Page 5: ...tain 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 eye flood with...

Page 6: ...rez vous que le niveau d lectrolyte de la batterie est correct avant de commencer la charge Ne tentez pas de charger une batterie gel e Recyclez la batterie quand elle est remplac e 1 0 TriStar Descri...

Page 7: ...he enclosure can be grounded using the ground terminal in the wiring compartment The TriStar is protected from faults electronically with automatic recovery There are no fuses or mechanical parts insi...

Page 8: ...nto 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 Canadia...

Page 9: ...70 amp res pour le TriStar PWM 45 et 90 amp res pour le TriStar PWM 60 M WARNING Installation must comply with all US National Electrical Code and Canadian Electrical Code requirements Breakers and fu...

Page 10: ...ltage is the same as the nominal battery voltage Do not install a TriStar in a sealed compartment with batteries Never open the TriStar access cover unless both the solar and battery power has been di...

Page 11: ...cated behind the negative power terminals Each switch is numbered The solar battery charging functions that can be adjusted with the DIP switches follow Control Mode Battery Charging 1 System Voltage...

Page 12: ...ches Number 2 3 System Voltage Voltage Switch 2 Switch 3 Auto Off Off 12 Off On 24 On Off 48 On On Auto Select 1 2 3 4 5 6 7 8 DIP ON 12 Volts 1 2 3 4 5 6 7 8 DIP ON ON OFF 24 Volts 1 2 3 4 5 6 7 8 DI...

Page 13: ...some types of telecom equipment or radios the TriStar can be converted to an On Off method of solar charge regulation It should be noted that the On Off solar charge regulation is much less effective...

Page 14: ...0 56 Nm 5 in lb of torque The maximum length allowed for each battery voltage sense wire is 30 meters 98 ft The battery sense terminal has polarity Be careful to connect the battery positive terminal...

Page 15: ...er NEC 690 45 A and NEC Table 250 122 minimum sizes for copper grounding wire are TS MPPT 45 10 AWG 5 mm2 TS MPPT 60 M 8 AWG 8 mm2 OR of the same or greater cross sectional area as the PV wires Connec...

Page 16: ...rform However the operator should be familiar with the basic operation and care of the TriStar as described below 3 1 Operator s Tasks Use the push button as needed see 3 2 below Check the LEDs for st...

Page 17: ...LVD 0 30V 0 60V 1 20V LVD 0 15V 0 30V 0 60V LVD The load status LEDs are determined by the LVD voltage plus the specified transition voltages As the battery voltage rises or falls each voltage transi...

Page 18: ...polarity will be damaged Be very careful to connect loads to the controller with correct polarity See Section 5 4 DIP switch fault R Y G sequencing If a DIP switch is changed while there is power to t...

Page 19: ...d instructions are available on our website 3 6 Inspection and Maintenance WARNING RISK OF ELECTRICAL SHOCK NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROM DC INPUT AND MAY BE ENERGIZED...

Page 20: ...troller to the battery is recommended This allows a precise battery voltage input to the controller and more accurate battery charging See Section 4 3 for more information Temperature Compensation All...

Page 21: ...ing may go into PWM absorption almost every day If the battery temperature is colder the charging will begin to regulate too soon and the battery may not be recharged with a limited solar resource If...

Page 22: ...ell drift Equalization cycles help to bring all the cells to the same voltage Mix the electrolyte In flooded batteries especially tall cells the heavier acid will fall to the bottom of the cell over t...

Page 23: ...e to level individual cells This is not an equalization and will not vent gas from sealed batteries that require up to 14 4V charging 12V battery This boost charge for sealed cells allows for adjustab...

Page 24: ...Battery 12V 24V 48V Switch LVD LVD LVD SOC LVDR LVDR LVDR off off off 11 1 22 2 44 4 8 12 6 25 2 50 4 off off on 11 3 22 6 45 2 12 12 8 25 6 51 2 off on off 11 5 23 0 46 0 18 13 0 26 0 52 0 off on on...

Page 25: ...ivert excess current to an external load As the battery becomes fully charged the FET switches are closed for longer periods of time to direct more current to the diversion load As the battery charges...

Page 26: ...on 4 3 Temperature Effects and Battery Voltage Sense 4 4 Equalization 4 5 Float 9 0 Battery Information 6 4 Selecting the Diversion Load It is critical that the diversion load be sized correctly If th...

Page 27: ...for the same voltage as the system voltage Nominal Voltage TriStar 45 TriStar 60 48V 2700W at 60V 3600W at 60V 24V 1350W at 30V 1800W at 30V 12V 675W at 15V 900W at 15V These maximum power ratings ar...

Page 28: ...leurs TriStar 6 6 Additional Information Visit Morningstar s website www morningstarcorp com for additional diversion charge control information The website provides expanded technical support for mo...

Page 29: ...alert the user to an existing fault or alarm In this situation the LED indicators will flash a particular sequence Section 3 3 references these sequences with their associated faults and alarms Flash...

Page 30: ...al support documents FAQs or to request technical support 9 0 Battery Information The standard battery charging programs in the TriStar controller as described in Section 4 2 are typical charging algo...

Page 31: ...calcium with low internal losses and very low water consumption throughout their life Selenium plates also have poor cycling life Lead Antimony Antimony cells are rugged and provide long service life...

Page 32: ...BUTOR AGENT OR EMPLOYEE IS AUTHORIZED TO MAKE ANY MODIFICATION OR EXTENSION TO THIS WARRANTY MORNINGSTAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITE...

Page 33: ...rol DIP Settings The NOTE The DIP switches should be changed only when there is no power to the controller Turn off disconnect switches and remove power to the controller before changing a DIP switch...

Page 34: ...ON Figure A1 3 Step 3 DIP Switches 2 3 The auto voltage selection occurs when the battery is connected and the TriStar starts up There should be no loads on the battery that might cause a discharged b...

Page 35: ...Custom Settings Figure A1 5 Step 3 DIP Switch 4 5 6 Select one of the 7 standard Lighting Control algorithms or select the custom DIP switch for special custom settings using the PC software The defau...

Page 36: ...ition With switches 1 and 7 in the ON position Diversion Charge Contol is set The OFF settings will operate as follows Switch Function 1 Must be ON to set Diversion Control 2 3 Auto voltage selected 4...

Page 37: ...rsion Switch 7 On 1 2 3 4 5 6 7 8 DIP ON ON OFF Figure A2 5 Step 3 DIP Switch 7 In the Diversion Charge Control mode DIP switch 7 must be in the ON position DIP Switch Number 8 Battery Equalization Eq...

Page 38: ...ond Float state G slow blink 1 second on 1 second off Battery State of Charge LED Indications when battery is charging G on 80 to 95 SOC G Y on 60 to 80 SOC Y on 35 to 60 SOC Y R on 0 to 35 SOC R on b...

Page 39: ...ds for CE marking Immunity EN 61000 4 3 2006 EN 61000 4 6 2009 Emissions CISPR 22 2008 Safety EN60335 1 EN60335 2 29 battery chargers EN 62109 1 2010 TrisStarTM MeterBusTM are trademarks of Morningsta...

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