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TriStar TRAKSTAR TS-MPPT-45, Installation, Operation And Maintenance Manual

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TriStar TRAKSTAR TS-MPPT-45 Installation, Operation And Maintenance Manual Download Page 6

11

TriStar MPPT Operator’s Manual

10

Getting Started

Getting Started

2.0 

2.1 Overview

Thank you for selecting the TriStar MPPT 150V solar charge controller with TrakStar

TM

 MPPT 

Technology. The TriStar MPPT 150V (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 150V battery charging process has been optimized for long battery life and 

improved 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 150V can provide for your 

PV system. 

2.2 Versions and Ratings

There are four versions of TriStar MPPT 150V controller:

TriStar-MPPT-30

•  maximum 30 amps continuous battery current
•  12, 24 and 48 Volt dc systems
•  maximum 150 Volt dc solar input voltage
•  RS-232 and MeterBus

TM

 communication ports

TriStar-MPPT-45

•  maximum 45 amps continuous battery current
•  12, 24 and 48 Volt dc systems
•  maximum 150 Volt dc solar input voltage
•  RS-232 and MeterBus

TM

 communication ports

TriStar-MPPT-60

•  maximum 60 amps continuous battery current
•  12, 24 and 48 Volt dc systems
•  maximum 150 Volt dc solar input voltage
•  RS-232, EIA-485, MeterBus

TM

, and Ethernet communication ports

TriStar-MPPT-60M

•  maximum 60 amps continuous battery current
•  12, 24 and 48 Volt dc systems
•  maximum 150 Volt dc solar input voltage
•  RS-232, EIA-485, MeterBus

TM

, and Ethernet communication ports

•  Includes on-board meter display

2.3 Features

The features of the TriStar MPPT 150V are shown in Figure 2-1 below.  An explanation of each      

feature is provided. 

12

11

13

9

16

15

3

2

1

17

4

5

8

6

14

10

7

Figure 2-1. TriStar MPPT 150V features

Summary of Contents for TRAKSTAR TS-MPPT-45

Page 1: ... www morningstarcorp com Solar Battery Charger With TrakStarTM Maximum Power Point Tracking Technology MODELS TS MPPT 30 TS MPPT 45 TS MPPT 60 TS MPPT 60M MAXIMUM POWER POINT TRACKING TRISTAR MPPT TM For the most recent manual revisions see the version at www morningstarcorp com ...

Page 2: ... Controller Installation 18 4 0 Operation 34 4 1 TrakStarTM MPPT Technology 34 4 2 Battery Charging Information 36 4 3 Push button 43 4 4 LED Indications 44 4 5 Protections Faults Alarms 46 4 6 Inspection and Maintenance 49 5 0 Networking and Communication 51 5 1 Introduction 51 5 2 Morningstar MeterBusTM 52 5 3 Serial RS 232 53 5 4 EIA 485 formerly RS 485 55 5 5 Ethernet 56 6 0 Troubleshooting 59...

Page 3: ... 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 symbol below Ground Symbol SAVE THESE INSTRUCTIONS This manual contains important safety installation and operating instructions for the TriStar MPPT 150V solar controller The following symbols are used...

Page 4: ...de système et d application CAUTION Do not open or mutilate batteries Released electrolyte is harmful to skin and may be toxic PRUDENCE Ne pas ouvrir ou mutiler les piles L électrolyte est nocif pour la peau et peut être toxique This charge controller is to be connected to DC circuits only These DC connections are identified by the symbol below Direct Current Symbol The TriStar MPPT 150V controlle...

Page 5: ...rotection et ayez de l eau fraîche à disposition en cas de contact avec l électrolyte Enlevez les montres bagues bijoux et autres objets mé talliques avant de travailler avec des piles Porter des bottes et des gants de caoutchouc Utiliser des outils avec poignées isolantes et évitez de placer des outils ou des objets métalliques sur le dessus de batteries Débrancher la source de charge avant de br...

Page 6: ...l help you make full use of the many advantages the TriStar MPPT 150V can provide for your PV system 2 2 Versions and Ratings There are four versions of TriStar MPPT 150V controller TriStar MPPT 30 maximum 30 amps continuous battery current 12 24 and 48 Volt dc systems maximum 150 Volt dc solar input voltage RS 232 and MeterBusTM communication ports TriStar MPPT 45 maximum 45 amps continuous batte...

Page 7: ...5 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 150V grounding terminal in the wiring compartment a permanent and reliable means for grounding shall be provided The clamping of the earthing shall be secured against accidental loosening The entry openings to ...

Page 8: ...Star MPPT 150V controller DIN rail compatible See section 5 2 for more details Relay Driver RD 1 The Relay DriverTM accessory enables the TriStar MPPT 150V 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...

Page 9: ... requirements are noted on occasion for convenience however the installer should have a complete understanding of NEC and UL requirements for photovoltaic installations Installation 3 0 Read through the entire installation section first before beginning installation Be very careful when working with batteries Wear eye protection Have fresh water available to wash and clean any contact with battery...

Page 10: ...through conduit or wire glands Table 3 1 below pro vides the knockout sizes and quantity on the TriStar MPPT 150V 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 gland...

Page 11: ...yhole on the TriStar MPPT 150V with the screw head Slide the TriStar MPPT 150V 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 150V with the screw head Slide the TriStar MPPT 150V down over the keyhole 11 The ...

Page 12: ...harges 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 push button or when requested from the equalize menu on the TriStar meter Automatic equalization will occur accord in...

Page 13: ...t être raccourci si la totalité de la longueur n est pas nécessaire Assurez vous de réinstaller la bobine en ferrite sur l extrémité du RTS si une longueur de câble est enlevée Cette bobine assure la conformité avec les normes d émissions électromagnétiques Step 6 Grounding and Ground Fault Interruption WARNING This unit is not provided with a GFDI device This charge controller must be used with a...

Page 14: ...occur if the polarity is reversed but the controller cannot read a reversed sense voltage Connecting the voltage sense wires to the RTS terminal will cause an alarm If a TriStar meter is installed check the TriStar Settings to confirm the Voltage Sense and the RTS if installed are both present and detected by the controller MSViewTM PC software can also be used to confirm the voltage sense is work...

Page 15: ...of array terminals The battery positive terminal has a red cover the solar positive terminal has a yellow cover REMARQUE Pour la conformité CNE le TriStar MPPT 150V doit être installé selon des méthodes de câblage conformes à la dernière édition du Code électrique national NFPA 70 PRUDENCE Risque d incendie et de décharge électrique Branchez les bornes de la batterie avant la connexion des bornes ...

Page 16: ...ire des tensions de circuit ouvert supérieures à 150 Vdc à la lumière du soleil Vérifiez que le coupe circuit ou l interrupteur d entrée solaire a été ouvert déconnexion avant d installer les câbles du système Figure 3 7 Power terminal locations Connect the four 4 power conductors shown in figure 3 7 above in the following steps 1 Confirm that the system input and output disconnect switches are bo...

Page 17: ...TISSEMENT Risque d endommagement La connexion du réseau solaire sur la borne de la batterie endommagera le TriStar MPPT 150V de façon permanente AVERTISSEMENT Risque d endommagement La connexion du réseau solaire ou la connexion de la batterie avec une polarité inversée endommagera le TriStar MPPT 150V de façon permanente Confirm that the Solar and Battery polarities are correct Turn the battery d...

Page 18: ...cuit voltage Voc rating will not exceed the TriStar MPPT 150V 150 Volt maximum input voltage rating at worst case coldest module temperature The solar module documentation should provide Voc vs temperature data Higher solar input voltage results in lower solar input current for a given input power High voltage solar input strings allow for smaller gauge solar wiring This is especially helpful and ...

Page 19: ...battery from long term overcharge The green SOC LED will blink once every two 2 seconds during Float charging Once in Float stage loads can continue to draw power from the battery In the event that the system load s exceed the solar charge current the controller will no longer be able to maintain the battery at the Float set point Should the battery voltage remain below the Float set point for a c...

Page 20: ...if the battery is fully recharged However a solar charged battery is seldom completely recharged so the soft lead sulfate crystals harden over a period of time Only a long controlled overcharge or equalization at a higher voltage can reverse the hardening of sulfate crystals Preparation for Equalization First confirm that all of the system loads are rated for the equalization voltage Consider that...

Page 21: ...normal Absorption duration Float Time out Figure 4 4 Float exit time out charging profile After entering Float stage the controller will only exit Float if the battery voltage remains below Float voltage for 60 cumulative minutes In figure 4 4 a system load turns on at 3 30 hrs when the controller is in Float stage runs for one hour and turns off at 4 30 hrs The load current draw is larger than th...

Page 22: ...battery The controller will begin Absorption or limit equalization at a lower battery voltage because the controller measures a higher voltage at the controller s terminals than is the actual battery voltage For example if the controller is programmed to start Absorption at 14 4V when the controller sees 14 4V at its battery terminals the true battery voltage would only be 14 1V if there is a 0 3V...

Page 23: ... R R Battery service is required all three LEDs blinking until service is reset battery service notification is only enabled in custom settings or when any custom edit is programmed Battery Status General state of charge See battery SOC LED indications below Absorption state G blinking second on second off Equalization state G fast blink 2 5 times per second Float state G slow blink 1 second on 1 ...

Page 24: ...s been working the LED s will indicate a failure However if the controller is restarted with a failed RTS the controller may not detect that the RTS is connected and the LEDs will not indicate a problem A TriStar meter or the PC software can be used to determine if an RTS is detected and working properly Battery Voltage Sense Failure G R sequencing with constant yellow If a fault in the battery se...

Page 25: ... the controller Use of the RTS is recom mended for proper battery charging 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 battery sense wire is disconnected Inspect the battery sense connections This alarm is set when the voltage at the battery sense ...

Page 26: ...neously Table 5 1 below provides a summary of supported features for each communication interface MeterBus RS 232 EIA 485 Ethernet Display system network data on a TriStar meter Connect a TSMPPT to a Relay Driver or other MS Accessory Connect multiple TSMPPT together in a network View and log data with MSViewTM PC Software View logged data stored in the TriStar MPPT 150V internal memory Update Tri...

Page 27: ... five 5 controllers can be networked together with a single hub Multiple hubs can be daisy chained together to allow networks of up to 14 controllers and a meter Refer to the HUB 1 and TriStar Meter manuals for more information about Morningstar Meter BusTM networking 5 3 Serial RS 232 The serial port connection on the TriStar MPPT 150V is a standard 9 pin isolated RS 232 port See figure 3 5 for t...

Page 28: ...nnect the TriStar MPPT 150V to other Morningstar controllers with the RSC 1 Serial to EIA 485 Adapter sold separately bridge an Ethernet connection through a TriStar MPPT 150V to an EIA 485 network The EIA 485 port has four 4 connections Power Data A Data B and Ground Data A B are differentially driven data lines that carry the network data Power and Ground connections pro vide power to the networ...

Page 29: ...gram for both scenarios is shown in figure 5 3 below Ethernet Cross over Cable Figure 5 3 Ethernet network diagrams Factory Default Network Settings DHCP enabled Live View Web Address http tsmppt serial number IP 192 168 1 253 if DHCP is not enabled Subnet Mask 255 255 255 0 Gateway 192 168 1 1 Primary DNS Server 169 254 1 1 MODBUS TCP IPTM Port 502 The Live View web address is unique to each cont...

Page 30: ...BETWEEN ALL TERMINALS AND GROUND BEFORE TOUCHING AVERTISSEMENT RISQUE DE CHOC ÉLETRIQUE NON ALIMENTATION OU AUX BORNES D ACCESSOIRES SONT ISOLÉS ÉLEC TRIQUEMENT DE L ENTRÉE DE C C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION DAN GEREUSE SOLAIRE SOUS CERTAINES CONDITIONS DE DÉFAILLANCE LA BATTERIE POURRAIT DEVENIR TROP CHARGÉE TEST ENTRE TOUTES LES BORNES ET LA MASSE AVANT DE TOUCHER WARNING Shock Hazard A...

Page 31: ... not work Power is supplied to the 4 wire bus on the Power Ground lines The bus requires voltage in the range 8 16 Vdc All bus connections are secure and each terminal is wired in parallel line A to line A line B to line B etc Problem Cannot connect to the controller via Ethernet Solution See the TriStar MPPT 150V Networking Companion Document available on our website LIMITED WARRANTY Morningstar ...

Page 32: ...t Voltage All 150 Volts dc Battery Operating Voltage Range All 8 72 Volts dc Nominal Maximum Input Power 12 Volt 400 Watts 600 Watts 800 Watts 24 Volt 800 Watts 1200 Watts 1600 Watts 48 Volt 1600 Watts 2400 Watts 3200 Watts Voltage Accuracy 12 24 V 0 1 50 mV 48 V 0 1 100 mV Self consumption tare loss All 1 3 2 7 Watts Transient Surge Protection All 4500 Watts port These power levels refer to the m...

Page 33: ... terminals Minimum wire size 0 25 mm2 24 AWG Maximum wire size 1 0 mm2 16 AWG Recommended torque 0 40 Nm 3 5 in lb Knockouts trade sizes M20 1 2 1 1 1 4 Mounting Vertical surface Environmental Operating Altitude Below 2000 meters Ambient Temperature Range 40 C to 45 C Storage Temperature 55 C to 85 C Humidity 100 N C Enclosure IP20 Type 1 indoor vented Protections Solar high voltage disconnect Sol...

Page 34: ...ater TriStar MPPT 24 Volt Efficiency output power Watts efficiency 99 98 97 96 95 94 93 92 91 90 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 0 89 33 Vmp 66 Vmp 98 Vmp 26 Vmp Battery 25 6 V 25 C ambient firmware ver 08 or later TriStar MPPT 48 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 26...

Page 35: ...at 30 C ambient temperature Ampacity for not more than three current car rying conductors in a raceway cable or earth buried 2 Voltage Drop Charts for 75 C Solid Copper Wire 1 Way Wire Distance feet 12 Volt System Wire Size AWG 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 Amps 2 0 27 8 30 3 33 4 37 1 41 7 47 7 55 6 66 7 83 4 111 2 1 0 22 0 24 1 26 5 29 4 33 1 37 8 44 ...

Page 36: ... at 30 C ambient temperature Ampacity for not more than three current car rying conductors in a raceway cable or earth buried 2 Voltage Drop Charts for 90 C Solid Copper Wire 1 Way Wire Distance feet 12 Volt System Wire Size AWG 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 Amps 2 0 27 8 30 3 33 4 37 1 41 7 47 7 55 6 66 7 83 4 111 2 1 0 22 0 24 1 26 5 29 4 33 1 37 8 44...

Page 37: ... 2005 EMC Immunity Industrial Environments EN 55022 2007 Class B EMC Emissions EN 60335 1 2002 Safety EN 60335 2 29 2005 Safety IEC 62109 1 2010 Safety of Power Converters in PV Systems TrisStar MPPTTM MeterBusTM are trademarks of Morningstar Corporation MODBUSTM and MODBUS TCP IPTM are trademarks of Modbus IDA www modbus ida org 2018 Morningstar Corporation All rights reserved MS 000946 v6 1 TUVR...

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