Morningstar TS-MPPT-60-600V-48-DB-TR Installation, Operation And Maintenance Manual Download

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Installation, Operation and Maintenance Man

ual

Solar Charging System Controller

www.morningstarcorp.com

Solar Battery Charger

with

TrakStar

Maximum Power Point Tracking Technology

MODELS

TS-MPPT-60-600V-48-DB-TR

TS-MPPT-60-600V-48-DB-TR-GFPD

MAXIMUM POWER POINT TRACKING

riStar MPPT

600V

with

Off-grid / Grid-tie

Transfer Switch

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

www.morningstarcorp.com

Summary of Contents for TS-MPPT-60-600V-48-DB-TR

Page 1: ...lar Battery Charger with TrakStarTM Maximum Power Point Tracking Technology MODELS TS MPPT 60 600V 48 DB TR TS MPPT 60 600V 48 DB TR GFPD MAXIMUM POWER POINT TRACKING TriStar MPPT 600V TM with Off grid Grid tie Transfer Switch For the most recent manual revisions see the version at www morningstarcorp com ...

Page 2: ...rsions and Ratings 13 2 4 Features 14 2 5 Optional Accessories 16 3 0 Installation 18 3 1 General Information 18 3 2 Wiring Zones 19 3 3 Conduit Knock outs and Wire Routing 21 3 4 Controller Installation 23 4 0 Operation 41 4 1 Using the Transfer Switch 41 4 2 TrakStarTM MPPT Technology 42 4 3 Battery Charging Information 43 4 4 GFPD 600V Operation 50 4 5 Push button 51 4 6 LED Indications and Aud...

Page 3: ...main 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 TS MPPT 600V TR solar controller The following symbols are us...

Page 4: ...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 TS MPPT 600V TR controller must be installed by a qualified technician in accordance wi...

Page 5: ...s de protection 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...

Page 6: ...ime to read this operator s manual and become familiar with the controller This will help you make full use of the many advantages the TS MPPT 600V TR can provide for your PV system 2 2 Regulatory Information NOTE This section contains important information for safety and regulatory requirements The TS MPPT 600V TR controller should be installed by a qualified technician according to the electrica...

Page 7: ...ient or re locate the receiving antenna Increase the separation between the equipment and receiver Connect the equipment into 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 Canadian ICES 003 Cet appareil numerique de la classe B est conforme a la norme NMB 0...

Page 8: ... 232 Port 9 pin serial connector female 8 EIA 485 Port Four 4 position screw terminal for EIA 485 bus connections 9 Battery Breaker 63A rating pre wired Battery disconnect point 10 Battery Terminal Blocks and battery terminal connection points 11 Grounding Terminal Block A chassis terminal for equipment grounding 12 Solar Terminal Blocks and solar terminal connection points 13 Connections Points o...

Page 9: ...ith a Morningstar controller s MeterBus port for monitoring and programming using MSView PC software 19 Solar Terminal Bridge yellow Isolates high voltage PV wiring from low voltage wiring area 20 and Solar Power Terminals pre wired and solar terminal connection points Optional TS MPPT 60 600V 48 DB TR GFPD Box 21 Breaker Mounting Plate removable Pre wired and mounted GFPD sensor and breaker assem...

Page 10: ... requirements for photovoltaic installations Solar and battery fuses or DC breakers are required in the system These protection devices are external to the TS MPPT 600V TR controller and must be 90 amps or lower for the 60 amp TS MPPT 600V TR Maximum battery short circuit current rating must be less than the interrupt current rating of the battery over current protection device referenced above St...

Page 11: ...uantity provided on the TS MPPT 600V TR wiring box Knockout placement dimensions are on the inside front cover Figures 3 2 and 3 3 show knock out types The TS MPPT 600V TR wiring box provides continuous and separate paths for high voltage solar and low voltage battery COM wiring routing These allow wiring to pass be tween TS MPPT 600V TR controllers that are mounted side by side without the need f...

Page 12: ...he controller before removing the wiring box cover Never remove the cover when voltage exists on any of the TS MPPT 600V TR power connections PRUDENCE Risque de décharge électrique Déconnectez toutes les sources d alimentation du contrôleur avant d enlever le couvercle du boîtier de câblage Ne retirez jamais le couvercle en présence de tension sur une des connexions d alimentation du TriStar MPPT ...

Page 13: ...d batteries will corrode and destroy the TS MPPT 600V TR circuits CAUTION Risk of Burns Install the TS MPPT 600V TR in a location that prevents casual contact The TS MPPT 600V TR heatsink can become very hot during operation ATTENTION Risque de brûlures Installez le TS MPPT 600V TR dans un endroit qui empêche le contact occasionnel Le dissipateur de chaleur TS MPPT 600V TR peut devenir très chaude...

Page 14: ...higher UL rated communication cable AVERTISSEMENT Risque de décharge électrique Seulement acheminez les câbles de réseau dans le même conduit que les conducteurs d alimentation si tous les conducteurs sont évalués à 600 V AVERTISSEMENT Risque de décharge électrique Utilisez uniquement 300 volts ou supérieur UL câble de communication Connect the appropriate network cables to the TS MPPT 600V TR at ...

Page 15: ...ges 77 80 provide wire sizing information for connecting the solar array and battery bank to the TS MPPT 600V TR with a maximum of 2 voltage drop Minimum Wire Size Field Wiring Connections Only The NEC requires that the wires carrying the system current never exceed 80 of the conduc tor s current rating Table 3 2 below provides the minimum size of copper wire for battery output connections allowed...

Page 16: ...ding Block G Loose Leads for Termination at a GFPD or cut to length and connected at the Controller Solar Terminals Step G To Grid tie Inverter Solar Input Solar Array Inputs 48 Volt Battery Termination Up to 2 Strings A A B B C D D E E F F H H Grounding Block Grounding Block To Grid tie Inverter Solar Input Solar Array Inputs Figure 3 11 Power Connections with GFPD Box ...

Page 17: ...hten all factory pre wired screw terminal connections to specified torque values E Connect grid tie switch outgoing and wires to the grid tie inverter solar and input terminals WARNING Risk of Damage Be very certain that the solar connections are made with correct polarity Turn on the solar array breaker disconnect and measure the voltage on the open wires BEFORE connecting to the TS MPPT 600V TR ...

Page 18: ...magnetic emissions standards PRUDENCE Le TS MPPT 600V TR ne compense pas la température des paramètres de charges si le RTS n est pas utilisé PRUDENCE Endommagement de l équipement Ne placez jamais la sonde de température dans un élément de batterie Le RTS et la batterie seraient endommagés REMARQUE Le câble de RTS peut être raccourci si la totalité de la longueur n est pas nécessaire Assurez vous...

Page 19: ... This stage limits input current so that the Absorption voltage is maintained As the battery becomes more charged the charging current continues to taper down until the battery is fully charged Float Stage When the battery is fully charged the charging voltage will be reduced to the Float voltage setting Equalize Stage During an equalization cycle the charging voltage will be held constant at the ...

Page 20: ...des règlements locaux Use a copper wire to connect the grounding terminal in the wiring box to earth ground Per NEC 690 45 and NEC Table 250 122 the minimum size for copper grounding wire is 1 TriStar MPPT 600V unit 60A 10 AWG 8 mm2 OR of the same or greater cross sectional area as the PV wires Also follow any additional local grounding code regulations that may apply The grounding terminal is ide...

Page 21: ...amage ONLY disconnect the battery from the TS MPPT 600V TR AFTER the solar input has been disconnected Damage to the controller may result if the battery is removed while the TS MPPT 600V TR is charging AVERTISSEMENT Risque d endommagement Le TS MPPT 600V TR SEULEMENT déconnecter la batterie APRÈS l entrée solaire a été déconnectée Le contrôleur pourrait endommager si la batterie est retirée quand...

Page 22: ...he Vmp and battery voltage the greater the current boost Current boost can be substantial in systems where the solar array is of a higher nominal voltage than the battery as described in the next section 4 3 Battery Charging 4 Stage Charging The TS MPPT 600V TR has a 4 stage battery charging algorithm for rapid efficient and safe battery charging Figure 4 0 shows the sequence of the stages NIGHT N...

Page 23: ...ain battery types benefit from a periodic boost charge to stir the electrolyte level the cell voltages and complete the chemical reactions Equalize charging raises the battery voltage above the standard absorption voltage so that the electrolyte gasses The green SOC LED will blink rapidly two 2 times per second during equalization charging The duration of the equalize charge is determined by the s...

Page 24: ...or nominal 48 Volt battery banks Settings Switches 4 5 6 Battery Type Absorp Stage Volts Float Stage Volts Equalize Stage Volts Absorp Time Minutes Equalize Time Minutes Equalize Interval Days off off off 1 Gel 56 00 54 80 150 off off on 2 Sealed 56 60 54 80 57 60 150 60 28 off on off 3 Sealed 57 20 54 80 58 40 150 60 28 off on on 4 AGM Flooded 57 60 54 80 60 40 180 120 28 on off off 5 Flooded 58 ...

Page 25: ...uns continuously for 60 min However because the Float exit timer is cumulative multiple momentary load events that pull the battery voltage below Float voltage for a combined 60 minute duration will also force an exit from the Float stage Float Cancel Voltage 1 00 2 00 3 00 4 00 5 00 6 00 49 20 V Bulk Absorption Float Cancel Voltage time hrs Float cancelled this charge cycle Figure 4 5 Float cance...

Page 26: ... systems to prevent current from following any unintended paths It is critical to detect any stray current and to interrupt break the circuit until safe operation can be restored Any current imbalance between the and conductors of a circuit indicates a ground fault Morningstar s GFPD 600V will detect this condition and break the circuit on both the and legs ensuring interruption 4 5 Push button Th...

Page 27: ...faults R Y G sequencing Remote Temperature Sensor RTS G Y Y R sequencing Battery voltage sense G Y Y R sequencing Solar Over Current Y R G sequencing Battery State of Charge LED Indications G 80 to 95 SOC G Y 60 to 80 SOC Y 35 to 60 SOC Y R 0 to 35 SOC R battery is discharging Refer to the Specifications Section 9 0 for the State of Charge voltages Note that because these State of Charge LED displ...

Page 28: ... circuit open circuit or loose terminal occurs after the battery sense has been working the LEDs will indicate a failure If the control ler is restarted with the failure still present the controller may not detect that the battery sense is connected and the LEDs will not indicate a fault A TriStar meter or the PC software can be used to determine if the battery sense is working properly Settings D...

Page 29: ...controller was not factory calibrated Return the controller to an authorized Morningstar dealer for service 5 0 Networking and Communication 5 1 Introduction The TS MPPT 600V TR provides several communication options The TS MPPT 600V TR uses a proprietary protocol for the MeterBusTM network and the non proprietary open standard MODBUSTM and MODBUS TCP IPTM protocols for RS 232 EIA 485 and ethernet...

Page 30: ...twork Up to five 5 controllers can be networked together with a single hub Multiple hubs can be daisy chained together to allow networks of up to 15 controllers and 2 meters 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 TS MPPT 600V TR is a standard 9 pin isolated RS 232 port See figure...

Page 31: ...network with custom charge settings using MSViewTM PC software connect the TS MPPT 600V TR to other Morningstar controllers with the RSC 1 Serial to EIA 485 Adapter sold separately bridge an Ethernet connection through a TS MPPT 600V TR 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 d...

Page 32: ...ed information about Ethernet connectivity and networking refer to the Morningstar Communications Document on our website at http www morningstarcorp com Network Information Connect to the TS MPPT 600V TR via an Ethernet network LAN WAN or connect the controller directly to a PC using an ethernet cross over cable Use CAT 5 or CAT 5e twisted pair Ethernet cables with RJ 45 connectors A network diag...

Page 33: ...T 600V TR logs up to 200 days of daily data The controller always logs the stan dard values listed below Using MSView the controller can be configured to log additional option al values each 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 Entered Floa...

Page 34: ...sequence see Section 4 4 Faults Alarms of this manual to determine the cause If a TriStar Meter 2 600V is connected the diagnostics menu will display reported faults and alarms Testing and Troubleshooting 6 0 If the LED indications 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 TS MPPT 600V TR solar in...

Page 35: ...PT 600V TR Operator s Manual Your TS MPPT 600V TR will provide years of reliable and trouble free service The unit contains no electromechanical parts such as relays or cooling fans that can wear out and fail Additionally there are no user serviceable parts inside the controller 7 1 Important Safety Instructions SAVE THESE INSTRUCTIONS This manual contains important safety installation and operati...

Page 36: ...icle 690 of the National Electrical Code for the installation location Mount the TS MPPT 600V TR indoors Prevent exposure to the elements and do not allow water to enter the controller Install the TS MPPT 600V TR in a location that prevents casual contact The TS MPPT 600V TR heatsink can become very hot during operation Use insulated tools when working with batteries Avoid wearing jewelry during i...

Page 37: ...DENCE Lorsque le remplacement des piles utilisez correctement nombre spécifié tailles types et les évaluations basées sur conception 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 Servicing of batteries should be perfo...

Page 38: ...torque values Inspect the system earth grounding for all components Verify all grounding conductors are appropriately secured to earth ground Table 7 1 Maintenance Schedule 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 brancher ou di...

Page 39: ...iding unparalleled customer support MS Support Scope 1 Determining correct or failed functionality of a Morningstar product or system of Morningstar devices It is expected that owners operators will use manuals including troubleshooting sections before requesting technical support 2 Providing product warranty replacements in accordance with the terms of Morningstar s warranty policy 3 Assisting wi...

Page 40: ...SPECIFICATIONS Electrical TS MPPT 60 600V 48 DB TR TS MPPT 60 600V 48 DB TR GFPD Nominal System Voltage 48 volts 48 volts Maximum Battery Current 60 amps 60 amps 63A breaker included Maximum Solar Input Voltage 600 volts dc 600 volts dc Battery Operating Voltage Range 16 72 volts dc 16 72 volts dc Maximum Operating Input Current 15 amps 15 amps Nominal Maximum Input Power 3200 watts 3200 watts Vol...

Page 41: ...TS and Battery Sense Terminals 24 AWG 0 25 mm2 16 AWG 1 0 mm2 Recommended Torques 5 16 in Power Board Screws 10 14 AWG 35 in lb 3 95 N m use 45 in lb 5 08 N m for 10 solid wire 8 AWG 40 in lb 4 52 N m 4 6 AWG 45 in lb 5 08 N m 2 3 AWG 50 in lb 5 65 N m 10 Battery Terminal Block Screws 10 14 AWG 20 in lb 2 26 N m 8 AWG 25 in lb 2 83 N m 6 AWG 35 in lb 3 95 N m 5 16 in Battery Terminal Block Screws ...

Page 42: ...igure 9 1 Battery Current vs Array Voltage OVER VOLTAGE RANGE Vb 40 V Vb 50 V 1 5 A IN P U T C U R R E N T L IM IT 60 Amp Battery Current Limit 60 Amp Battery Current Limit Vb 30 V 60 Amp Battery Current Limit Vb 20 V 60 Amp Battery Current Limit 60 Amp Battery Current Limit Vb 60 V 0 100 200 300 400 500 600 500 1000 1500 2000 2500 3000 3500 INPUT VOLTAGE Volts POWER Watts Output Power vs Array In...

Page 43: ...5 5 1 5 8 6 8 8 1 10 2 13 6 6 2 1 2 3 2 6 2 8 3 2 3 7 4 3 5 1 6 4 8 5 4 1 3 1 5 1 6 1 8 2 0 2 3 2 7 3 2 4 0 5 3 2 5 0 8 0 9 1 0 1 1 1 3 1 4 1 7 2 0 2 5 3 4 Table 9 2 Maximum 1 way wire distance for 48V systems stranded copper 2 Voltage Drop Charts for 75 C Stranded Copper Wire 1 Way Wire Distance feet 48 Volt System 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 Amps 00...

Page 44: ...acity at 50 C ambient temperature Exceeds wire ampacity at 40 C ambient temperature Exceeds wire ampacity 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 Stranded Copper Wire 1 Way Wire Distance feet 48 Volt System 60 Amps 55 Amps 50 Amps 45 Amps 40 Amps 35 Amps 30 Amps 25 Amps 20 Amps 15 Amps...

Page 45: ...roller 1 way distance Shaded cells in the table indicate that the current exceeds the ampacity of the wire for a given ambient temperature as defined in the following table Wire Ampacity Key Exceeds wire ampacity at 60 C ambient temperature Exceeds wire ampacity at 50 C ambient temperature Exceeds wire ampacity at 40 C ambient temperature Exceeds wire ampacity at 30 C ambient temperature This prod...

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