Morningstar TriStar TS-MPPT-30 Installation And Operation Manual Download Page 68

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TriStar

, TriStar MPPT

, MeterBus

are trademarks of Morningstar Corporation

MODBUS

and MODBUS TCP/IP

are trademarks of Modbus IDA. www.modbus-ida.org

RoHS

MS-ZMAN-TSMPPT-01

v04

03/2010

For product and purchase inquiries contact:

www.ecodirect.com

Summary of Contents for TriStar TS-MPPT-30

Page 1: ...troller 8 Pheasant Run Newtown PA 18940 USA email info morningstarcorp com www morningstarcorp com Solar Battery Charger with TrakStarTM Maximum Power Point Tracking Technology Models TS MPPT 60 TS MP...

Page 2: ...Dimensions in Inches Millimeters...

Page 3: ...troller 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...

Page 4: ...ou fonction importante pour l utilisation s re et correcte du contr leur Safety Information Read all of the instructions and cautions in the manual before beginning installation There are no user serv...

Page 5: ...ted 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 ba...

Page 6: ...ducteurs et des coupe circuits de dimensions adapt es La borne de mise la terre se trouve dans le compartiment de c blage et est identifi e par le symbole ci dessous Ce contr leur de charge ne doit tr...

Page 7: ...stallation 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...

Page 8: ...ment 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...

Page 9: ...9 TriStar 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...

Page 10: ...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 connec...

Page 11: ...ding 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 eq...

Page 12: ...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 com...

Page 13: ...PPT 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 quipement ou risque d explos...

Page 14: ...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...

Page 15: ...E Risque de d charge lectrique D connectez toutes les sources d alimentation du contr leur avant d enlever le couvercle du bo tier de c blage Ne retirez jamais le couvercle en pr sence de tension sur...

Page 16: ...ds in the knockout openings to protect wiring from sharp edges PRUDENCE Risque de d charge lectrique Utilisez toujours des bagues des connecteurs des raccordements collets ou des fouloirs dans les ouv...

Page 17: ...es 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 cl...

Page 18: ...w 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...

Page 19: ...rging 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 t...

Page 20: ...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 Ta...

Page 21: ...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 ne...

Page 22: ...at is stamped into the wiring box just below the terminal Figure 3 4 Ground Symbol Do not connect the system negative conductor to this terminal NEC requires the use of an exter nal ground fault prote...

Page 23: ...ires 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 c...

Page 24: ...tached The ports are located inside the conduit wir ing box on the lower circuit board as shown in figure 3 5 Figure 3 5 TriStar MPPT network port locations EIA 485 Connection The four 4 position EIA...

Page 25: ...jack features two 2 indicator LEDs for connection status and network traf fic Use CAT 5 or CAT 5e twisted pair cable and RJ 45 plugs If possible pull the network cable through conduit before crimping...

Page 26: ...for copper and aluminum conductors Use UL listed Class B 300 Volt stranded wire only Good system design generally requires large conductor wires for the solar and battery con nections that limit volta...

Page 27: ...th each TriStar MPPT model is listed in table 3 3 Model Minimum battery circuit fuse breaker rating TS MPPT 45 1 25 x 45 Amps 56 3 Amps TS MPPT 60 1 25 x 60 Amps 75 0 Amps Table 3 3 Minimum battery ci...

Page 28: ...on the open battery wires BEFORE connecting to the TriStar MPPT Disconnect the battery breaker disconnect before wiring to the controller AVERTISSEMENT Risque d endommagement Assurez vous que la conne...

Page 29: ...nnecting the solar array or battery connection with reverse polarity will permanently damage the TriStar MPPT AVERTISSEMENT Risque d endommagement La connexion du r seau solaire sur la borne de la bat...

Page 30: ...MPPT 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 foll...

Page 31: ...ltage Amps x Volts is greatest which falls on the knee of the solar module I V curve as shown on the left in Figure 4 1 Because traditional controllers do not always operate at the Vmp of the solar ar...

Page 32: ...on Stage When the battery has recharged to the Absorption voltage setpoint constant voltage regulation is used to maintain battery voltage at the Absorption setpoint This prevents heating and excessiv...

Page 33: ...fy all system loads are rated for the temperature compensated Equalize voltage before beginning an Equalization charge CAUTION Equipment Damage Excessive overcharging and gassing too vigorously can da...

Page 34: ...for your particular battery 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 c...

Page 35: ...losses Check that the battery plates are covered Equalize a Sealed Battery The Battery Charging Settings table see table 4 1 in this section shows one sealed battery setting with an Equalization cycl...

Page 36: ...includes gel and AGM batteries Table 4 1 Battery charging settings for each selectable battery type Shared Settings Value Units Absorption Extension Voltage 12 50 Volts Absorption Extension Time Absor...

Page 37: ...attery voltage remains below Float voltage for 30 cumulative minutes In figure 4 4 a system load turns on at 4 30 hrs when the controller is in Float stage runs for 1 2 hour and turns off at 5 00 hrs...

Page 38: ...The diagram shows where Float stage would have occurred if Float was not cancelled Equalize Timeout Figure 4 6 Equalize timeout charging profile The charging profile in figure 4 6 shows an Equalize T...

Page 39: ...o sense wires sized from 1 0 to 0 25 mm2 16 to 24 AWG can be used for battery voltage sense Because these wires carry no current the voltage at the TriStar will be identical to the battery voltage A 2...

Page 40: ...d see Section 4 4 Equalization will only occur if the selected battery type has an equalization stage Stop an equalization that is in progress This will be effective in either the manual or auto matic...

Page 41: ...repeat until the fault is cleared General Transitions Controller start up G Y R one cycle Equalize request start G Y R G Y R G G Equalize cancelled G Y R G Y R R R Battery service is required all 3 L...

Page 42: ...f Charge LED displays are for all battery types and system de signs they are only approximate indications of the battery charge state Ethernet Jack Indications In addition to the SOC LEDs two 2 small...

Page 43: ...sized solar array will not operate at peak power The solar array should be less than the TriStar MPPT Nominal Maximum Input Power rating for optimal performance See section 8 0 for more informa tion S...

Page 44: ...ondition After all settings have been modified the controller must be reset by removing and then restoring power to the controller The new programmed settings will be used after the power reset Firmwa...

Page 45: ...ng Heatsink Temperature Sensor Open Shorted The heatsink temperature sensor is damaged Return the controller to an authorized Morningstar dealer for service Battery Sense Out of Range Disconnected A b...

Page 46: ...ded batteries make sure the water level is correct Wet cell water levels should also be checked frequently according to the manufacturer s recommendations Inspect the system earth grounding for all co...

Page 47: ...T Multiple communication ports can be used simultaneously For example a TriStar MPPT may be connected to a MeterBusTM network for on site system metering connected to the internet for remote monitorin...

Page 48: ...mote Meter 2 TS RM 2 are required not included A MeterBus Hub model HUB 1 is required for MeterBus networks containing multiple TriStar MPPT controllers The ports on the hub are electrically isolated...

Page 49: ...C software log real time data with MSViewTM PC software configure ethernet settings update controller firmware with MSLoadTM firmware utility NOTE The RS 232 and EIA 485 ports share hardware Both port...

Page 50: ...nection between a TriStar MPPT and a PC or other serial device Firmware updates can only be programmed through the RS 232 connection The serial connection is not typically used for multi controller ne...

Page 51: ...n data lines that carry the network data Power and Ground connections pro vide power to the network The TriStar MPPT does not supply power to the EIA 485 network therefore an external power source is...

Page 52: ...net connection provides include program custom settings with MSViewTM PC software monitor the controller from a web browser modify controller settings from a web browser log and monitor the system wit...

Page 53: ...Open a web browser on any PC on the network Enter the Live View web address in the address bar of the web browser The TriStar MPPT main Live View webpage will load Links are provided to real time dat...

Page 54: ...ch day The maximum number of days that can be stored decreases as the number of logged values increases Standard Values Minimum Battery Voltage Maximum Battery Voltage Daily Events Equalize triggered...

Page 55: ...are normal check the fuses breakers and wiring connections in the solar array wiring With a multi meter check the array voltage directly at the TriStar MPPT solar input terminals Input voltage must b...

Page 56: ...controller or device on the EIA 485 network has been programmed with a unique MODBUS ID A serial cross over Null Modem cable is used for the connection between the PC and the Morningstar RSC 1 485 Ad...

Page 57: ...rningstar will pay the return shipping charges if the repairs are covered by the warranty WARRANTY EXCLUSIONS AND LIMITATIONS This warranty does not apply under the following conditions Damage by acci...

Page 58: ...ture compensated setpoints Absorption Float Equalize HVD Charging Setpoints Settings Switches Battery Type Absorp Stage Float Stage Equalize Stage Absorp Time Equalize Time Equalize Timeout Equalize I...

Page 59: ...mm 5 58 Product Weight 4 14 kg 9 lbs 2 oz Shipping Weight 2 pcs carton 11 6 kg 25 lbs 9oz Power terminals Minimum wire size 2 5 mm2 14 AWG Maximum wire size 35 mm2 2 AWG Recommended torque 5 65 Nm 50...

Page 60: ...60 Specifications Deratings Figure 8 7 Battery Current vs Array Voltage Figure 8 8 Battery Current vs Heatsink Temperature...

Page 61: ...400 450 500 550 600 650 700 750 0 88 16 5 Vmp 13 Vmp 66 Vmp 98 Vmp Battery 12 8 V 25 C ambient firmware ver 08 or later TriStar MPPT 24 Volt Efficiency output power Watts efficiency 99 98 97 96 95 94...

Page 62: ...Volt Efficiency output power Watts efficiency 100 99 98 97 96 95 94 93 92 91 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 0 90 52 Vmp 66 Vmp 83 Vmp 98 Vmp Battery 51 2 V 25 C...

Page 63: ...94 with A1 and A3 Class B1 Safety EN60335 1 and EN60335 2 29 battery chargers UL1741 INVERTERS CONVERTERS AND CONTROLLERS AND INTERCONNECTION SYSTEM EQUIPMENT FOR USE WITH DISTRIBUTED ENERGY SOURCES F...

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Page 66: ...6 1 35 1 47 1 61 1 79 2 02 2 31 2 69 3 23 4 04 5 38 10 0 85 0 93 1 02 1 13 1 27 1 46 1 70 2 04 2 55 3 40 6 0 53 0 58 0 64 0 71 0 80 0 91 1 07 1 28 1 60 2 13 4 0 33 0 36 0 40 0 44 0 50 0 57 0 67 0 80 1...

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Page 68: ...of Morningstar Corporation MODBUSTM and MODBUS TCP IPTM are trademarks of Modbus IDA www modbus ida org RoHS 2010 Morningstar Corporation All rights reserved MS ZMAN TSMPPT 01 v04 03 2010 For product...

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