Morningstar MPPT Solar Charging System Controller User Manual
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Installation, Operation and Maintenance Manu
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For the most recent manual revisions, see the version at:
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Solar Charging System Controller
TAR MPPT
www.morningstarcorp.com
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TrakStarTM Maximum Power Point Tracking Technology
MAXIMUM POWER POINT TRACKING
Solar Battery Charger
With
www.morningstarcorp.com
MODELS
TS-MPPT-30
TS-MPPT-45
TS-MPPT-60
TS-MPPT-60M
Dimensions in Inches [Millimeters] TABLE OF CONTENTS
1.0 Important Safety Instructions 4
2.0 Getting Started 10
2.1 Overview 10
2.2 Versions and Ratings 10
2.3 Features 11
2.4 Regulatory Information 13
2.5 Optional Accessories 14
3.0 Installation 16
3.1 General Information 16
3.2 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 MeterBus
5.3 Serial RS-232 53
5.4 EIA-485 (formerly RS-485) 55
5.5 Ethernet 56
TM
52
6.0 Troubleshooting 59
7.0 Warranty and Claim Procedure 61
8.0 Specications 63
9.0 Certications 73
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1.0 Important Safety Instructions
SAVE THESE INSTRUCTIONS.
This manual contains important safety, installation and operating instructions for the
TriStar MPPT 150V solar controller. The following symbols are used throughout this manual to
indicate potentially dangerous conditions or mark important safety instructions:
WARNING:
Indicates a potentially dangerous condition. Use extreme caution
when performing this task.
CAUTION:
Indicates a critical procedure for safe and proper operation of the
controller.
NOTE:
Indicates a procedure or function that is important for the safe and
proper operation of the controller.
Informations de Sécurité
• Lisez toutes les instructions et les avertissements gurant dans le manuel avant de commencer l’installation.
• Le TriStar MPPT 150V ne contient aucune pièce réparable par l’utilisateur. Ne démontez
pas ni ne tentez de réparer le contrôleur.
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 DANGEREUSE SOLAIRE. SOUS CERTAINES CONDITIONS DE DÉFAILLANCE, LA BATTERIE
POURRAIT DEVENIR TROP CHARGÉE. TEST ENTRE TOUTES LES BORNES ET LA MASSE
AVANT DE TOUCHER.
External solaire et la batterie se déconnecte sont nécessaires.
• Déconnectez toutes les sources d’alimentation du contrôleur avant d’installer ou de régler
le TriStar MPPT 150V.
• Le TriStar MPPT ne contient aucun fusible ou interrupteur. Ne tentez pas de réparer.
AVERTISSEMENT :
Indique une condition potentiellement dangereuse. Faites preuve
d’une prudence extrême lors de la réalisation de cette tâche.
PRUDENCE :
Indique une procédure critique pour l’utilisation sûre et correcte du
contrôleur.
REMARQUE :
Indique une procédure ou fonction importante pour l’utilisation sûre et
correcte du contrôleur.
Safety Information
• Read all of the instructions and cautions in the manual before beginning installation.
• There are no user serviceable parts inside the TriStar MPPT 150V. Do not disassemble
or attempt to repair the controller.
WARNING: RISK OF ELECTRICAL SHOCK.
NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROM
DC INPUT, AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN FAULT CONDITIONS, BATTERY COULD BECOME OVER-CHARGED. TEST BETWEEN
ALL TERMINALS AND GROUND BEFORE TOUCHING.
• External solar and battery disconnects are required.
• Disconnect all sources of power to the controller before installing or adjusting the
TriStar MPPT 150V.
• Installez des fusibles/coupe-circuits externes selon le besoin.
Installation Safety Precautions
WARNING:
This unit is not provided with a GFDI device. This charge controller must be
used with an external GFDI device as required by the Article 690 of the National
Electrical Code for the installation location.
• Mount the TriStar MPPT 150V indoors. Prevent exposure to the elements and do not allow
water to enter the controller.
• Install the TriStar MPPT 150V in a location that prevents casual contact. The
TriStar MPPT 150V heatsink can become very hot during operation.
• Use insulated 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 near the battery bank.
• Power connections must remain 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 identied by the
symbol below.
• There are no fuses or disconnects inside the TriStar MPPT 150V Do not attempt to repair.
Ground Symbol
5TriStar MPPT Operator’s Manual4 Important Safety Instructions
• This charge controller is to be connected to DC circuits only. These DC connections are identied
by the symbol below:
Direct Current Symbol
The TriStar MPPT 150V controller must be installed by a qualified technician in accordance with the
electrical regulations of the country where the product is installed. A means of disconnecting all
power supply poles must be provided. These disconnects must be incorporated in the fixed wiring.
A permanent, reliable earth ground must be established with connection to the wiring compartment
ground terminal.
The grounding conductor must be secured against any accidental detachment. The knock-outs in
the wiring compartment must protect wires with conduit or rubber rings.
Précautions de Sécurité D’installation
• Ce contrôleur de charge ne doit être connecté qu’à des circuits en courant continu. Ces connex-
ions CC sont identiées par le symbole ci-dessous:
Le contrôleur TriStar MPPT 150V doit être installé par un technicien qualié conformément aux
règlementations électriques du pays où est installé le produit.
Un moyen d’assurer la déconnexion de tous les pôles de l’alimentation doit être fourni. Cette décon-
nexion doit être incorporée dans le câblage xe.
À l’aide de la borne de mise à la masse du TriStar MPPT 150V (dans le compartiment de câblage),
un moyen permanent et able de mise à la terre doit être fourni. La xation de la mise à la terre doit
être xée contre tout desserrage accidentel.
Les ouvertures d’entrée au compartiment de câblage du TriStar MPPT 150V doivent être
protégées avec un conduit ou une bague.
AVERTISSEMENT: L’appareil n’est pas fourni avec un dispositif GFDI. Ce
contrôleur de charge doit être utilisé avec un dispositif GFDI externe tel que requis
par l’Article 690 du Code électrique national de l’emplacement de l’installation.
• Montez le TriStar MPPT 150V à l’intérieur. Empêchez l’exposition aux éléments et la pénétration
d’eau dans le contrôleur.
• Installez le TriStar MPPT 150V dans un endroit qui empêche le contact occasionnel. Le dissipateur
de chaleur peut devenir très chaud pendant le fonctionnement.
• Utilisez des outils isolés pour travailler avec les batteries.
• Évitez le port de bijoux pendant l’installation.
• Le groupe de batteries doit être constitué de batteries du même type, fabricant et âge.
• Ne fumez pas à proximité du groupe de batteries.
• Les connexions d’alimentation doivent rester serrées pour éviter une surchauffe excessive d’une
connexion desserrée.
• Utilisez des conducteurs et des coupe-circuits de dimensions adaptées.
• La borne de mise à la terre se trouve dans le compartiment de câblage et est identiée par le
symbole ci-dessous estampillé dans le boit:
Battery Safety
WARNING: A battery can present a risk of electrical shock or burn from large amounts
of short-circuit current, re, or explosion from vented gases. Observe proper precautions.
AVERTISSEMENT: Une batterie peut présenter a ris que de choc électrique ou de brûlure
de grandes quantités de court-circuit curlouer, incendie ou explosion de ventilé gaz.
Observer précautions appropriées.
WARNING: Risk of Explosion.
Proper disposal of batteries is required. Do not dispose of batteries in re. Refer to
local regulations or codes for requirements.
AVERTISSEMENT: Risque d’Explosion.
Au rebut des piles est nécessaire. Ne pas jeter les piles dans le feu. Se référer aux régle
mentations locales ou des codes pour les exigences.
CAUTION:
based on application and system design
PRUDENCE: Lorsque le remplacement des piles, utilisez correctement nombre spécifié,
tailles, types et les évaluations basées sur conception de système et d’application.
When replacing batteries, proper specied number, sizes types and ratings
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.
6
Important Safety Instructions
7TriStar MPPT Operator’s Manual
• Servicing of batteries should be performed, or supervised, by personnel knowledgeable about
batteries, and the proper safety precautions.
• Be very careful when working with large lead-acid batteries. Wear eye protection and have fresh
water available in case there is contact with the battery acid.
• Remove watches, rings, jewelry and other metal objects before working with batteries.
• Wear rubber gloves and boots
• Use tools with insulated handles and avoid placing tools or metal objects on top of batteries.
• Disconnect charging source prior to connecting or dis-connecting battery terminals.
• Determine if battery is inadvertently grounded. If so, remove the source of contact with ground.
Contact with any part of a grounded battery can result in electrical shock. The likelihood of such
a shock can be reduced if battery grounds are removed during installation and maint enance
(applicable to equipment and remote battery supplies not having a grounded supply circuit).
• Carefully read the battery manufacturer’s instructions before installing / connecting to, or removing
batteries from, the TriStar MPPT.
• Be very careful not to short circuit the cables connected to the battery.
• Have someone nearby to assist in case of an accident.
• Explosive battery gases can be present during charging. Be
release the gases.
• Never smoke in the battery area.
certain there is enough ventilation to
• Des gaz explosifs de batterie peuvent être présents pendant la charge. Assurez-vous qu’une venti-
lation sufsante évacue les gaz.
• Ne fumez jamais dans la zone des batteries
• En cas de contact de l’électrolyte avec la peau, lavez avec du savon et de l’eau. En cas de contact
de l’électrolyte avec les yeux, rincez abondamment avec de l’eau fraîche et consultez un médecin.
• Assurez-vous que le niveau d’électrolyte de la batterie est correct avant de commencer la charge.
Ne tentez pas de charger une batterie gelée.
• Recyclez la batterie quand elle est remplacée.
• If battery acid comes into contact with the skin, wash with
eye, ood with fresh water and get medical attention.
• Be sure the battery electrolyte level is correct before starting charging. Do not attempt to charge a frozen
battery.
• Recycle the battery when it is replaced.
• Entretien des batteries devrait être effectué ou supervisé, par un personnel bien informé sur les
piles et les précautions de sécurité appropriées.
• Soyez très prudent quand vous travaillez avec des grandes batteries au plomb. Portez des lunettes
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 de brancher ou dis-reliant les bornes de la batterie.
• Utilisez des outils isolés et évitez de placer des objets métalliques dans la zone de travail.
• Déterminer si batterie repose par inadvertance. Dans l’afrmative, supprimer la source du contact
avec le sol. Contact avec n’importe quelle partie d’une batterie mise à la terre peut entraîner un
choc électrique. La probabilité d’un tel choc peut être réduite si des motifs de batterie sont supprimés pendant l’installation et maintentretien (applicable à l’équipement et les fournitures de pile de
la télécommande n’ayant ne pas un circuit d’alimentation mise à la terre *).
soap and water. If the acid contacts the
About this Manual
This manual provides detailed installation and usage instructions for the TriStar MPPT 150V
controller. Only qualied electricians and technicians who are familiar with solar system design
and wiring practices should install the TriStar MPPT 150V. The usage information in this manual
is intended for the system owner/operator.
• Lisez attentivement les instructions du fabricant de la batterie avant d’installer / connexion à ou
retrait des batteries du TriStar MPPT.
• Veillez à ne pas court-circuiter les câbles connectés à la batterie.
• Ayez une personne à proximité qui puisse aider en cas d’accident.
8
Important Safety Instructions
9TriStar MPPT Operator’s Manual
Getting Started2.0
2.1 Overview
Thank you for selecting the TriStar MPPT 150V solar charge controller with TrakStarTM 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 nds 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
2.3 Features
The features of the TriStar MPPT 150V are shown in Figure 2-1 below. An explanation of each
feature is provided.
1
2
17
16
15
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 battery current
• 12, 24 and 48 Volt dc systems
• maximum 150 Volt dc solar input voltage
• RS-232 and MeterBus
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
TriStar-MPPT-60M
• maximum 60 amps continuous battery current
• 12, 24 and 48 Volt dc systems
TM
communication ports
TM
, and Ethernet communication ports
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13
12
11
10
9
3
4
5
6
7
8
• maximum 150 Volt dc solar input voltage
• RS-232, EIA-485, MeterBus
• Includes on-board meter display
TM
, and Ethernet communication ports
Figure 2-1. TriStar MPPT 150V features
11TriStar MPPT Operator’s Manual10 Getting Started
1 - Heatsink
Aluminum heatsink to dissipate controller heat
2.4 Regulatory Information
2 - Mounting Hanger
Keyhole slot for mounting
3 - Settings Switches
Eight (8) settings switches to congure operation of the TriStar MPPT 150V
4 - Battery Positive Terminal (red)
Power connection for Battery (+)
5 - Remote Temperature Sensor Terminals
Connection point for a Morningstar RTS (optional) to remotely monitor battery temperature
6 - LED Indicators
Three state of charge (SOC) LED indicators show charging status and controller faults
7 - MeterBusTM Port
RJ-11 socket for Morningstar MeterBusTM network connections
8 - Battery Voltage Sense Terminals
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 connections (TS-MPPT-60 model only)
11 - Wiring Box with Conduit Knockouts
Termination points for wiring conduit and wire glands
12 - Wiring Box Cover
Sheet metal wiring box cover protects power connections
13 - Serial RS-232 Port
9-pin serial connector (female)
14 - EIA-485 Port
Four (4) position screw terminal for EIA-485 bus connections (TS-MPPT-60 model only)
15 - Solar Positive Terminal (yellow)
Power connection for Solar (+)
16 - Common Negative Power Terminals
Two (2) negative terminals for negative system cable termination
NOTE:
This section contains important information for safety and
regulatory requirements.
The TriStar MPPT 150V controller should be installed by a qualied technician according to the
electrical rules of the country in which the product will be installed.
TriStar MPPT 150V controllers comply with the following EMC standards:
• Immunity: EN61000-6-2:1999
• Emissions: EN55022:1994 with A1 and A3 Class B1
• Safety: EN60335-1 and EN60335-2-29 (battery chargers)
A means shall be provided to ensure all pole disconnection from the power supply. This discon-
nection shall be incorporated in the xed 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 the TriStar MPPT 150V wiring compartment shall be protected with conduit
or with a bushing.
FCC requirements:
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This
device may not cause harmful interference, and (2) this device must accept any interference received, including
interference that may cause undesired operation.
Changes or modications not expressly approved by Morningstar for compliance could void the user’s authority to
operate the equipment.
Note:
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15
of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instruction manual, may cause harmful interference to radio communication. However,
there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the equipment on and off, the user
is encouraged to try to correct the interference by one or more of the following measures:
• Reorient or relocate 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.
17 - Push-button Switch
Manually reset from an error or fault, also used to start/stop a manual equalization.
12
Getting Started
This Class B digital apparatus complies with Canadian ICES-003.
Cet appareil numerique de la classe B est conforme a la norme NMB-003 du Canada.
13TriStar MPPT Operator’s Manual
2.5 Optional Accessories
Ethernet Meterbus Converter (EMC-1)
The following accessories are available for purchase separately from your authorized
Morningstar dealer:
TriStar Digital Meter 2 / TriStar Remote Meter 2 (Models: TS-M-2 / TSRM-2)
The TriStar Digital Meter mounts directly on the TS-MPPT controller, replacing the wiring box
cover. The TriStar Remote Meter can be ush mounted in a wall or into a standard duplex (2-
gang) electrical box. A 2 x 16 character display shows system operating information, error indications, and self-diagnostic information. Four (4) buttons make navigating the meter menus easy.
For systems where multiple TS-MPPT controllers are networked together, one (1) meter can
display full system information. The TriStar meters connect to the RJ- 11 MeterBusTM port on the
TriStar-MPPT.
Meter Hub (HUB-1)
A Morningstar MeterBusTM network with multiple controllers requires a Meter Hub for electrical isolation. The HUB-1 allows communication between MeterBusTM compatible Morningstar
products, including the TriStar MPPT 150V controller. DIN rail compatible. See section 5.2 for
more details.
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 currently available. The
EMC-1 supports any product with a MeterBus port by bridging MODBUS TCP/IP requests
between an Ethernet connection and a connected Morningstar device.
Relay Driver (RD-1)
The Relay DriverTM accessory enables the TriStar MPPT 150V to control external devices. Four
(4) relay control ports can be congured (in various combinations) to perform the following tasks:
• generator control (2-, 3-, and 4-wire congurations)
• dry contacts for alarms and other signals
• advanced load control
• vent fan control
• DIN rail compatible or surface mount
For more information on the Relay Driver, visit our website at www.morningstarcorp.com or inquire with your local Morningstar dealer.
EIA-485 / RS-232 Communications Adapter (RSC-1)
Connect one or more TriStar MPPT 150V controllers to a PC or to other serial devices using the
RSC-1 EIA-485 adapter. The adapter converts an RS-232 serial interface to EIA-485 compliant
signals. An LED shows network activity and errors. DIN rail compatible.
14
Getting Started
15TriStar MPPT Operator’s Manual
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Installation3.0
3.1 General Information
The mounting location is important to the performance and operating life of the controller. The
environment must be dry and protected from water ingress. If required, the controller may be
installed in a ventilated enclosure with sufcient air ow. Never install the TriStar MPPT 150V in
a sealed enclosure. The controller may be mounted in an enclosure with sealed batteries, but
never with vented/ooded batteries. Battery fumes from vented batteries will corrode and destroy
the TriStar MPPT 150V circuits.
Multiple TriStars can be installed in parallel on the same battery bank to achieve higher charging
current. Additional parallel controllers can also be added in the future. Each TriStar MPPT 150V
must have its own solar array.
• Read through the entire installation section rst 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 acid.
• Use insulated tools and avoid placing metal objects near the batteries.
• Explosive battery gases may be present during charging. Be certain there is sufcient ventilation
to release the gases.
• Do not install in locations where water can enter the controller.
• Loose power connections and/or corroded wires may result in resistive connections that melt
wire insulation, burn surrounding materials, or even cause re. Ensure tight connections and use
cable clamps to secure cables and prevent them from swaying in mobile applications.
• Stranded wires to be connected to the terminals should be prepared rst with e.g. clamped
copper heads, tinned-wire ends, etc. to avoid the possibility of one conductor free out of the
connection screw, and possible contact with the metal enclosure.
WARNING: Installation must conform to all requirements of the US National Electrical
Code and the Canadian Electrical Code.
AVERTISSEMENT: Installation doit être conforme à toutes les requirments US
National Electrical Code et Code Canadien d’Electricité.
CAUTION: Equipment Damage or Risk of Explosion
Never install the TriStar MPPT 150V in an enclosure with vented/ooded
batteries. Battery fumes are ammable and will corrode and destroy the
TriStar MPPT 150V circuits.
CAUTION: Equipment Damage
When installing the TriStar MPPT 150V in an enclosure, ensure sufcient
ventilation. Installation in a sealed enclosure will lead to over-heating and
a decreased product lifetime.
PRUDENCE : Endommagement de l’équipement ou risque
d’explosion
N’installez jamais le TriStar MPPT 150V dans une enceinte avec des
batteries à évent/à électrolyte liquide. Les vapeurs des batteries sont
inammables et corroderont et détruiront les circuits du TriStar MPPT
150V.
• Preset charging proles are generally designed for lead acid batteries. Custom settings can be
used for varied charging requirements (see sections 3.2 and 4.2 for details). Note that some
battery types may not be compatible.
• The TriStar MPPT 150V battery connection may be wired to one battery, or a bank of batteries.
The following instructions refer to a singular battery, but it is implied that the battery connection
can be made to either one battery or a group of batteries in a battery bank.
• The TriStar MPPT 150V uses stainless steel fasteners, an anodized aluminum heat sink, and
conformal coating to protect it from harsh conditions. However, for acceptable service life, extreme temperatures and marine environments should be avoided.
• The TriStar MPPT 150V prevents reverse current leakage at night, so a blocking diode is not
required in the system.
• Solar and battery fuses or DC breakers are required in the system. These protection devices are
external to the TriStar MPPT 150V controller, and must be a maximum of 45 amps for the TSMPPT-30. 70 amps for the TS-MPPT 45 and 90 amps for the TS-MPPT-60.
• Maximum battery short-circuit current rating must be less than the interrupt current rating of the
battery over-current protection device referenced above.
Recommended Tools:
• Wire strippers
• Wire cutters
PRUDENCE : Endommagement de l’équipement
Assurez une ventilation sufsante en cas d’installation du TriStar MPPT
150V dans une enceinte. L’installation dans une enceinte hermétique
entraîne une surchauffe et une réduction de la durée de vie du produit.
The installation is straight-forward, but it is important each step is done correctly and safely. A
mistake can lead to dangerous voltage and current levels. Be sure to carefully follow each
instruction in this section. Read all instructions rst before beginning installation.
The installation instructions are for installation of a negative grounded system. National Electrical
Code (NEC) requirements are noted on occasion for convenience, however the installer should
have a complete understanding of NEC and UL requirements for photovoltaic installations.
• #2 & #0 Phillips screwdriver
• slotted screwdrivers
• Pliers
• Drill
• 3/32” (2.5 mm) drill bit
• Level
• hack saw (cutting conduit)
17TriStar MPPT Operator’s Manual16 Installation
3.2 Controller Installation
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Step 1 - Remove the wiring box cover
CAUTION: Shock Hazard
Disconnect all power sources to the controller before removing the wiring box cover. Never
remove the cover when voltage exists on any of the TriStar MPPT 150V 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.
Use a #2 Phillips screw driver to remove the four (4) screws that secure the wiring box cover as
shown in gure 3-1 below.
Step 2 - Remove the Knock-Outs
Knockouts are provided for routing cables through conduit or wire glands. Table 3-1 below provides 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 glands in the knockout openings to
protect wiring from sharp edges.
PRUDENCE : Risque de décharge électrique
Utilisez toujours des bagues, des connecteurs, des raccordements à collets ou des fouloirs dans
les ouvertures an de protéger le câblage des bords coupants.
CAUTION: Shock Hazard
Never route network cables in the same conduit as the power conductors.
Figure 3-1. Remove the wiring box cover.
If a TriStar Digital Meter 2 display is installed, be sure to disconnect the RJ-11 cable.
PRUDENCE : Risque de décharge électrique
N’acheminez jamais les câbles réseau dans le même conduit que les conducteurs
d’alimentation.
Plan the routing of each conductor that will connect to the TriStar MPPT 150V before removing
any knockouts. The 1/2” (M20) knockouts are ideal for routing network cables, which must be
placed in separate conduit.
18
Installation
19TriStar MPPT Operator’s Manual
Step 3 - Mount to a Vertical Surface
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3. Place a mark on the mounting surface at the top of the keyhole.
4. Remove the controller and drill a 3/32” (2.5 mm) hole at the drill mark.
CAUTION: Risk of Burns
Install the TriStar MPPT 150V in a location that prevents casual contact. The
TriStar MPPT 150V heatsink can become very hot during operation.
M6 Screw
Mounting Hanger
Figure 3-2. Attaching the mounting hanger
1. Attach the mounting hanger to the bottom of the TriStar MPPT 150V with the M6 screw pro-
vided as shown in gure 3-2.
2. Place the TriStar MPPT 150V on a vertical surface protected from direct sun, high temperatures, and water. The TriStar MPPT 150V requires at least 6” (150 mm) of clearance above
and below and at least 1” (25 mm) on each side for proper air ow as shown in gure 3-3
below.
5. Insert a #10 screw (included) into the top pilot hole. Do not tighten the screw completely.
Leave a 1/4” (6 mm) gap between the mounting surface and screw head.
6. Carefully align the keyhole 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 pre-drilled pilot holes should align with the mounting holes in the wiring box. Secure the
controller with two (2) #10 mounting screws.
12. Tighten the keyhole screw.
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
20
AT LEAST
WARM AIR
AT LEAST
1” (25 mm)
Figure 3-3. Required mounting clearance for air ow.
COOL AIR
6” (150 mm)
AT LEAST
6” (150 mm)
Installation
Switches 2 & 3: System Voltage
Four (4) system voltage congurations are available as shown in the table below:
System Voltage Switch 2 Switch 3
Auto OFF OFF
12 OFF ON
24 ON OFF
48 ON ON
The “auto” setting allows the TriStar MPPT 150V to detect the system voltage automatically on
start up. The test is only performed at start up and the detected system voltage will never change
during operation.
Generally, it is best to choose a specic system voltage. The auto detect feature should only be
used in situations where the system voltage is unknown ahead of time or in systems where the
system voltage may change periodically.
21TriStar MPPT Operator’s Manual
Switches 4, 5, & 6: Battery Charging Settings
!
!
It is important to select the battery type that matches the system battery to ensure proper charg-
ing and long battery life. Refer to the specications provided by the battery manufacturer and
choose a setting that best ts the recommended charging prole.
Settings
Switches
4 - 5 - 6
off-off-off 1 - Gel 14.00 13.70
off-off-on 2 - Sealed* 14.15 13.70 14.40 28
off-on-off 3 - Sealed* 14.30 13.70 14.60 28
off-on-on 4 - AGM/Flooded 14.40 13.70 15.10 28
on-off-off 5 - Flooded 14.60 13.50 15.30 28
on-off-on 6 - Flooded 14.70 13.50 15.40 28
on-on-off 7 - L-16 15.40 13.40 16.00 14
on-on-on 8 - Custom Custom Custom Custom Custom
* “Sealed” battery type includes gel and AGM batteries
Battery
Type
Absorp.
Stage
(Volts)
Float
Stage
(Volts)
Equalize
Stage
(Volts)
Equalize
Interval
(Days)
All settings are for 12 Volt nominal systems. Multiply the charge voltage settings by 2 for 24 Volt
systems or by 4 for 48 Volt systems. A description of each setting is provided below. See section 4.3 for full details on battery charging and a description of each of the settings in the battery
charging table.
Battery Type - The most common battery type associated with the specied charging settings.
Absorption Stage - 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
specied voltage setting.
Equalize Interval - The number of days between equalization charges when the controller is con-
gured for automatic equalizations (settings switch 7).
In both settings (auto and manual), the push-button can be used to start and stop battery equalization. If the selected battery charging setting does not have an equalization stage an equalization will never occur, even if requested manually.
Equalize Switch 7
manual OFF
automatic ON
Switch 8: Ethernet Security
The Ethernet Security switch enables or disables conguration of the TriStar MPPT 150V settings
through the Ethernet connection. When switch eight is set to disabled, write commands to the
TriStar MPPT 150V custom memory are not allowed. This a safety feature to prevent unintended
changes to custom settings, but it is not a replacement for proper network security.
Conguration via TCP/IP Switch 8
disabled OFF
enabled ON
NOTE:
Adjustment of network settings and custom set-points is always enabled via the
RS-232 and EIA-485 connections. The Ethernet Security switch only enables/
disables remote conguration via TCP/IP.
CAUTION: Risk of Tampering
The Ethernet Security settings switch does not block write commands to devices
bridged via EIA-485.
REMARQUE :
Le réglage des paramètres de réseau et des points de consignes personnalisés
est toujours activé par les connexions RS-232 et EIA-485. Le contacteur de
sécurité Ethernet n’active/désactive que la conguration à distance par TCP/IP.
PRUDENCE : Risque de tentative d’altération
Le contacteur des paramètres de sécurité Ethernet ne bloque pas les
commandes d’écriture sur les dispositifs reliés par EIA-485.
Switch 7: Battery Equalization
Choose between manual and automatic battery equalization charging. In the manual equalization 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-
ing to the battery program specied by settings switches 4, 5, & 6 in the previous step.
22
Installation
23TriStar MPPT Operator’s Manual
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