Morningstar TriStar Solar Charging System Controller User Manual

TM

TM

Solar Charging System Controller

Installation, Operation and

Maintenance Manual

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

www.morningstarcorp.com

MAXIMUM POWER POINT TRACKING

.....

Solar Battery Charging

.....

Load Control

.....

Diversion Control

www.morningstarcorp.com

MODELS

TS-45
TS-60

TS-60M

Table of Contents

This page inside front
COVER 2

(Please do not print this copy)

Important Safety Instructions

1.0 TriStar Description

1.1 Versions and Ratings

1.2 Operating Modes

1.3 Adjustability

1.4 General Use

1.5 Safety and Regulatory Information

1.6 Optional Accessories........................................................................

2.0 Installation

2.1 General Information

2.2 Installation Overview

2.3 Installation Steps

1. Remove the Cover

2. Mounting

3. Adjust DIP Switches

4. Remote Temperature Sensor

5. Battery Voltage Sense

6. System Wiring and Power-up

7. RS-232 Adjustments

8. Finish Installation

3.0 Operation

3.2 Push-button......................................................................................

3.3 LED Indications

3.4 Protections and Fault Recovery

3.5 Data-Logging

3.6 Inspection and Maintenance

3.1 Operator’s Tasks

............................................................................... 8

............................................................................. 8

..............................................................

.................................................................. .............. 15

........................................................................................ 27

4.0 Solar Battery Charging......

4.1 PWM Battery Charging

4.1.1 Four Stages of Solar Charging.........................................34

4.1.2 Battery Charging Notes.................................................... 34

4.2 Standard Battery Charging Programs

4.3 Temperature Effects & Battery Voltage Sense

4.3.1 Remote Temperature Sensor (RTS)................................36

4.3.2 Battery Voltage Sense......................................................37

4.4 Equalization.......................................................................................

4.4.1 Standard Equalization Programs......................................39

4.4.2 Typical qualizations...........................................................39

4.4.3 Preparation for equalization..............................................40

4.4.4 When to Equalize..............................................................40

4.4.5 Equalize a Sealed Battery?..............................................40

4.5 Float..................................................................................................41

i MORNINGSTAR CORPORATION

................................................................... 1

........................................................................... 7

.....................................................................7

....................................................................... 7

............................................ 10

11

..............................

.................................................................... 12

................................................................ 13

..................................................................... 14

................................................................ 15

.............................................................. 16

................................................. 21

............................................................. 22

................................................. 23

.............................................................. 26

................................................................... 26

........................................................................ 27

......................................................................... 28

................................................. 29

............................................................................. 32

...................................................... 32

........................................................... 34

................................................................ 34

........ ................................. 35

................................36

(continued)

12

27

38

5.0 Load & Lighting Control

5.1 General Load & Lighting Control Notes

5.1.1 Inductive Loads............................................................. 42

5.1.2 Parallel TriStars....................................................................42

5.1.3 Reverse Polarity...................................................................42

5.2 Load Control Settings

5.3 LVD Warning

..................................................................................44

6.0 Diversion Charge Control

6.1 Diversion Charge Control...................

6.2 Diversion Current Ratings

6.3 Standard Diversion Battery Charging Programs

6.4 Selecting the Diversion Load

6.4.2 Defintion of Terms........................................................47

6.4.3 Load Power Ratings.....................................................48

6.4.4 Maximum Diversion Load............................................48

6.4.5 Minimum Diversion Load.............................................49

6.5 NEC Requirements

6.5.1 Second Independent Means.......................................50

6.5.2 150 Percent Rating..................................................... 50

6.6 Additional Information.....

6.3.1 Battery Charging References......................................46

6.4.1 Suitable Loads for Diversion...

7.0 Custom Settings with PC Software...........................................

7.1 Connection to a Computer

7.2 Using the PC Software

7.3 Changing Set-points

7.4 Finish

8.0 Self-Test / Diagnostics.........................................................................53

8.1 General Troublshooting..............................................................53

8.2 Troubleshooting Solar Charging................................................54

8.3 Troubleshooting Load Control................................................... 54

8.4 Troubleshooting Diversion Control.................................. ..........54

9.0 Battery Information (reference).......................................................... 55

9.1 Sealed Batterie

9.2 Flooded Batteries

9.3 L-16 Cells

10.0 Warranty...............................................................................................58

11.0 Specifications...................................................................................... 59

Appendix 1 - Load and Lighting Control DIP Switch Settings ......................61

Appendix 2 - Diversion Charge Control DIP SwitchSettings........................66

Appendix 3 - LED Indications........................................................................ 70

12.0 Certifications...................................................................................... 73

...........................................................................................52

.................................................................................. 57

............................................................... 42

............................................42

.................................................................. 42

....................................................................

.......................................... 44

.......................................................... 45

.......................... 45

...............................................................

............................... .........

.................................................................... 50

..............................................................50

............................................................51

.................................................................51

.....................................................................52

s...........................................................................55

....................................................................... 56

44

47

.47

51

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS.

This manual contains important safety, installation, operating and mantenance
instructions for the TriStar-PWM 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 to the safe and
proper operation of the controller.

CONSIGNES IMPORTANTES DE SÉCURITÉ
CONSERVEZ CES INSTRUCTIONS.

Ce manuel contient des instructions importantes de sécurité, d’installations et
d’utilisation du contrôleur solaire. TriStar-PWM. Les symboles suivants sont utilisés

dans ce manuel pour indiquer des conditions potentiellement dangereuses ou des
consignes importantes de sécurité.

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-PWM. Do not
disassemble or attempt to repair the controller.

continued...

1 MORNINGSTAR CORPORATIONii TABLE OF CONTENTS

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-PWM.

• There are no fuses or disconnects inside the TriStar-PWM Do not attempt to
repair.

Informations de Sécurité

• Lisez toutes les instructions et les avertissements gurant dans le manuel
avant de commencer l’installation.

• Le TriStar-PWM ne contient aucune pièce réparable par l’utilisateur. Ne dé­montez pas ni ne tentez de réparer le contrôleur.

AVERTISSEMENT: RISQUE DE CHOC ÉLECTRIQUE. NON

ALIMENTATION OU AUX BORNES D’ACCESSOIRES SONT ISOLÉS
ÉLECTRIQUEMENT 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-PWM.

• Le TriStar MPPT ne contient aucun fusible ou interrupteur. Ne tentez pas de
réparer.

• 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-PWM indoors. Prevent exposure to the elements and do not
allow water to enter the controller.

• Install the TriStar-PWM in a location that prevents casual contact. The TriStar­PWM heatsink can become very hot during operation.

• Use insulated tools when working with batteries.

• Avoid wearing jewelry during installation.

IMPORTANT SAFETY INSTRUCTIONS

• The battery bank must be comprised of batteries of same type, make, and

. . .

age.

• IEC 62109 certified for use in negative ground or floating systems only

• 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 identied
by the symbol below:

Ground Symbol

• This charge controller is to be connected to DC circuits only. These DC

connections are identied by the symbol below:

Direct Current Symbol

The TriStar-PWM controller must be installed by a qualied 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 xed wiring.

A permanent, reliable earth ground must be established with connection to the
TriStar-PWM wiring compartment ground terminal.

The grounding conductor must be secured against any accidental detachment.
The knock-outs in the TriStar-PWM wiring compartment must protect wires with
conduit or rubber rings.

Précautions de Sécurité D’installation

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-PWM à l’intérieur. Empêchez l’exposition aux éléments et la
pénétration d’eau dans le contrôleur.

• Installez le MPPT ProStar dans un endroit qui empêche le contact occasion­nel. Le dissipateur de chaleur TriStar-PWM peut devenir très chaud pendant

3 MORNINGSTAR CORPORATION2

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.

• UL/IEC 62109 certié pour utilisation au négatif à la masse ou les systèmes

ottants seulement.

• 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

identiée par le symbole ci-dessous:

• Ces connexions CC sont identiées par le symbole ci-dessous:

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 risque 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 réglementations locales ou des codes pour les exigences.

CAUTION: When replacing batteries, use properly specied number,
sizes, types, and ratings 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.

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 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 disconnecting 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-PWM.

• 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

enough ventilation to release the gases.

• Never smoke in the battery area.

• If battery acid comes into contact with the skin, wash with
the acid contacts the eye, flood 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.

certain there is

soap and water. If

5 MORNINGSTAR CORPORATION4 IMPORTANT SAFETY INSTRUCTIONS

• 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’afrmative, 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).

• Lisez attentivement les instructions du fabricant de la batterie avant d’installer
/ connexion à ou retrait des batteries du TriStar-PWM.

• Veillez à ne pas court-circuiter les câbles connectés à la batterie.

• Ayez une personne à proximité qui puisse aider en cas d’accident.

• Des gaz explosifs de batterie peuvent être présents pendant la charge.

Assurez-vous qu’une ventilation sufsante 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.

1.0 TriStar Description

The TriStar is a technically advanced solar system controller. There are three
operating modes programmed into each TriStar. This manual describes solar battery
charging, and specific load control or diversion charge control instructions are
inserted where required.

This manual will help you to become familiar with the TriStar’s features and
capabilities. Some of these follow:

• ETL Listed (UL 1741) and cETL Listed (CSA-C22.2 No. 107.1)

• TUV Listed (IEC 62109)

• Complies with the US National Electrical Code

• Complies with the Canadian Electrical Code

• Complies with EMC and LVD standards for CE marking

• Rated for 12, 24, 48 volt systems, and 45 or 60 amps current

• Fully protected with automatic and manual recovery

• Seven standard charging or load programs selected with DIP switches

• Adjustability by means of an RS-232 connection with PC software

• Continuous self-testing with fault notification

• LED indications and push-button functions

• Terminals sized for 35mm2 (#2 AWG) wire

• Includes battery voltage sense terminals

• Digital meter options (mounted to TriStar or remote)

• Optional remote battery temperature sensor

• 5-year warranty (see Section 10.0)

1.1 Versions and Ratings

There are two standard versions of TriStar controllers:
TriStar-45:

Rated for maximum 45 amps continuous current

(solar, load or diversion load)

Rated for 12, 24, 48 Vdc systems
TriStar-60:

Rated for maximum 60 amps continuous current

(solar, load or diversion load)

Rated for 12, 24, 48 Vdc systems
TriStar-60M:

Rated for maximum 60 amps continuous current

(solar, load or diversion load)

Rated for 12, 24, 48 Vdc systems
Includes on-board meter display

1.0

1.2 Operating Modes

There are three distinct and independent operating modes programmed into
each TriStar. Only one mode of operation can be selected for an individual
TriStar. If a system requires a charging controller and a load controller, two
TriStars must be used.

6

IMPORTANT SAFETY INSTRUCTIONS

7 MORNINGSTAR CORPORATION

1.3 Adjustibility

Eight DIP switches permit the following parameters to be adjusted at the
installation site:

DIP switch Solar Battery Charging
1 Battery charge control mode
2-3 Select battery voltage
4-6 Standard battery charging programs
7 Manual or automatic equalization
8 PWM charging or on-off charging

DIP switch Load Control
1 DC load control mode
2-3 Select battery voltage
4-6 Standard low voltage disconnects and reconnects
7 not used for load control
8 not used for load control

DIP switch Diversion Charge Control
1 DC load control mode
2-3 Select battery voltage
4-6 Standard diversion charge control programs
7 Select diversion charge control mode
8 Manual or automatic equalization

In addition to the DIP switches, the TriStar provides for additional adjust ments
using a PC program. An RS-232 connection between the TriStar and
a personal computer will enable extensive adjustments using PC software
from Morningstar’s website.

1.4 General Use

NOTE: This manual describes solar battery charging. Specific instructions for

the load control and diversion charge control modes are provided as notes
throughout this manual.

Solar overloads up to 130% of rated current will be tapered down instead of
disconnecting the solar. Over-temperature conditions will also taper the solar
input to lower levels to avoid a disconnect.

The NEC requires overcurrent protection externally in the system
Section 2.3 step 6)
enclosure.

Any number of TriStars can be connected in parallel to increase solar
charging current. TriStars can be paralleled ONLY in the battery charging
mode. DO NOT parallel TriStars in the load mode, as this can damage the
controller or load.

The TriStar enclosure is rated for indoor use. The controller is protected
by conformal coated circuit boards, stainless steel hardware, anodized
aluminum, and a powder coated enclosure, but it is not rated for corrosive
environments or water entry.

The construction of the TriStar is 100% solid state.
Battery charging is by a series PWM constant current charging, with bulk

charging, PWM absorption, float and equalization stages.
The TriStar will accurately measure time over long intervals to manage events

such as automatic equalizations or battery service notification.
Day and night conditions are detected by the TriStar, and no blocking diodes

are used in the power path.
LEDs, a push-button, and optional digital meters provide both status

information and various manual operations.
The date of manufacture can be found on the two bar code labels. One label

is on the back of the TriStar, and the other is in the wiring compartment. The
year and week of manufacture are the first four digits of the serial number. For
example:

year week serial #
03 36 0087

. There are no system disconnects inside the TriStar

(see

1.0

REMARQUE : Ce manuel décrit la charge de batteries solaires. Des
instructions spécifiques aux modes de contrôle du chargement et de contrôle
de la charge de diversion figurent en tant que remarques dans ce manuel.

The TriStar is suitable for a wide range of solar applications including homes,
telecom and industrial power needs.

TriStar controllers are configured for negative ground systems. There are no
parts in the controller’s negative leg. The 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 inside the TriStar to reset or change.

8 TRISTAR DESCRIPTION 9 MORNINGSTAR CORPORATION

1.5 Safety and Regulatory Information

NOTE: This section contains important information for safety and regulatory

requirements.

REMARQUE : Cette section contient des informations importantes relatives à
la sécurité et aux obligations réglementaires.

The TriStar controller is intended for installation by a qualified technician
according to electrical rules of each country in which the product will be
installed.

TriStar controllers comply with the following EMC standards:

Immunity: EN 61000-4-3: 2006;
Emissions: CISPR 22: 2008
Safety: EN60335-1 and EN60335-2-29 (battery chargers)

A means shall be provided to ensure all pole disconnection from the power
supply. This disconnection shall be incorporated in the fixed wiring.

Using the TriStar grounding terminal (in the wiring compartment), a perman ent
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 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 modifications 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.

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.

10 TRISTAR DESCRIPTION 11 MORNINGSTAR CORPORATION

EN 61000- 4-6: 2009

1.6 Optional Accessories

Remote Temperature Sensor (RTS)

If the temperature of the system battery varies more than 5˚C (9˚F) during the year,

temperature compensated charging should be considered. Because the battery’s
chemical reactions change with temperature, it can be important to adjust charging to
account for the temperature effects. The RTS will measure the battery temperature,
and the TriStar uses this input to adjust the charging as required.

The battery charging will be corrected for temperature as follows:

• 12 V battery – 0.030 Volts per ˚C (–0.017V per ˚F)

• 24 V battery – 0.060 Volts per ˚C (–0.033V per ˚F)

• 48 V battery – 0.120 Volts per ˚C (–0.067V per ˚F)

The RTS should be used only for battery charging and diversion control. Do not use
the RTS for load control. The charging parameters that are adjusted for temperature
include:

• PWM regulation

• Equalization

• Float

• High Voltage Disconnect
See Installation, Step 4, for connecting the RTS to the TriStar.

Digital Meter Displays

Two digital meters can be added to the TriStar at any time during or after installation.
One version is mounted on the controller (TS-M), the other is suitable for remote
locations (TS-RM). The manual for installation and operation of the meter displays is
included with the meter.

The display is a 2x16 LCD meter with backlighting. Four push-buttons are used to
scroll through the displays and to execute manual functions.

There are a series of display screens that provide information such as:

• operating information and data

• operating bar charts (voltage and current)

• alarms and faults

• diagnostics

• settings
In addition, there are various manual functions built into the meter. For example, the

meter can be used to reset Ah data or start/stop equalizations.
One of 5 languages can be selected for the meter.

Ethernet Communications Adapter (EMC-1)

This product is an Ethernet gateway that provides web monitoring services,
a Modbus TCP/IP server, and a local web page server. End users can
collect information about their off-grid PV system remotely. One EMC-1
supports all products with MeterBus ports by bridging MODBUS TCP/IP
requests to serve LiveView pages for each product.

USB Communications Adapter (UMC-1)

A modular unit that uses a USB-B plug, usually from a USB A-B
computer cable, and an RJ-11 plug to connect with a Morningstar
controller’s MeterBus port, for monitoring and programming using
MSView PC software.

1.0

2.0 TriStar Installation

The installation instructions describe solar battery charging. Specific
instructions for the load control and diversion modes are provided as notes.

2.1 General Information

The mounting location is important to the performance and operating life of
the controller. The environment must be dry and protected as noted below.
The controller may be installed in a ventilated enclosure with sealed batteries,
but never in a sealed battery enclosure or with vented batteries.

If the solar array exceeds the current rating of the controller, multiple TriStars
can be installed in parallel. Additional parallel controllers can also be added in
the future. The load controllers cannot be used in parallel. To parallel diversion
controllers, refer to Morningstar’s website.

If solar charging and load control are both required, two separate controllers
must be used.

Stranded wires to be connected to the terminals should be prepared

rst with e.g. clamped copper heads, etc. to avoid the possibility of one

conductor free out of the connection screw, and possible contact with the
metal enclosure.

WARNING: Solar and battery fuses or DC breakers
are required in the system. These protection devices are external to the

controller, and must be a maximum of 70 amps for the TriStar-PWM-45, and 90
amps for the TriStar-PWM-60/M.

2.2 Installation Overview

The installation is straightforward, but it is important that 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 Section 2.3 and observe
all cautions and warnings.

The following diagrams provide an overview of the connections and the
proper order.

Load

or

+

Solar
Array

Solar + / Load +

+

–

+

RTS

Sense

Battery +

+ –

Battery

(Not for

Load)

–

–

2.0

Battery –

AVERTISSEMENT: Solaire et batterie fusibles ou
disjoncteurs DC sont nécessaires dans le système. Ces dispositifs
de protection sont externes au contrôleur, et doivent être un maximum de 70
ampères pour le TriStar-PWM-45, et 90 ampères pour le TriStar-PWM-60/M.

WARNING: Installation must comply with all US National
Electrical Code and Canadian Electrical Code requirements. Breakers
and fuses may require lower ratings than referenced above, so as not to exceed

any specic wire ampacity.

Figure 2.2a Installation Wiring for Solar Charging and Load Control

Step Solar Charging and Load Control

1. Remove the access cover

2. Mount the TriStar using the enclosed template.

3. Adjust the 8 switches in the DIP switch. Each switch must be in the

Solar – / Load –

correct position.

4. Attach the RTS if battery charging will be temperature compensated

AVERTISSEMENT: Installation doit être conforme à
toutes les requirments US National Electrical Code et Code Canadien
d'Electricité. Disjoncteurs et fusibles peuvent exiger des cotes inférieures que
mentionnés ci-dessus de manière à ne pas pour dépasser n'importe quel fils
particulier admissible.

(not for load control).

5. Connect battery voltage sense wires (recommended).

6. Connect the battery power wires to the TriStar. Then connect the
solar array wires (or load).

7. Connect a computer to the TriStar if making adjustments with
PC software.

Maximum battery short-circuit current rating must be less than the interrupt

8. Replace the cover.

current rating of the battery over-current protection device referenced above.

12 TRISTAR INSTALLATION 13 MORNINGSTAR CORPORATION

Hydro

—

Wind

—

Solar

Source +

Source –

Figure 2.2b Installation Wiring for Diversion Charge Control

+

+

–

+

Sense

Battery +

+ –

Battery

RTS

–

–

Battery –

Diversion –

Diversion +

NOTE: TriStar negative terminals are common negative.

Steps #3 and #6 are required for all installations.
Steps #4, #5, and #7 are optional.

Step Diversion Charge Control

1. Remove the access cover

2. Mount the TriStar using the enclosed template.

3. Adjust the 8 switches in the DIP switch. Each switch must be in the
correct position.

4. Attach the RTS if battery charging will be temperature compensated.

5. Connect battery voltage sense wires (recommended).

6. Connect the battery power wires to the TriStar. Then connect the
diversion load wires.

Recommended tools:

• wire cutter • phillips screwdrivers • wire stripper

• torque wrench (to 50 in-lb) • slotted screw drivers • flashlight
Before starting the installation, review these safety notes:

• Do not exceed a battery voltage of 48V nominal (24 cells). Do not use a
battery less than 12V (6 cells).

• Do not connect a solar input greater than a nominal 48V array for battery
charging. Never exceed a Voc (open-circuit voltage) of 125V.

• Charge only 12, 24, or 48 volt lead-acid batteries when using the standard
battery charging programs in the TriStar.

• Verify the nominal charging voltage 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 disconnected.

• Never allow the solar array to be connected to the TriStar with the battery
disconnected. This can be a dangerous condition with high open-circuit solar
voltages present at the terminals.

Follow the installation steps in order: #1 through #8

Step 1 - Remove the Cover

Remove the 4 screws in the front cover. Lift the cover until the top edge clears
the heat sink, and set it aside. If an LCD meter display is attached
to the cover, disconnect the RJ-11 connector at the meter for access.

CAUTION: Do not remove the cover if power is present at any of the

terminals. Verify that all power sources to the controller are disconnected.

PRUDENCE : N’enlevez pas le couvercle en cas de tension à une des
bornes. Vérifiez que toutes les sources d’alimentation au contrôleur sont
déconnectées.

Step 2 - Mounting

Locate the TriStar on a wall protected from direct sun, high temperatures, and
water. Do not install in a confined area where battery gasses can accumulate.

2.0

Step Diversion Charge Control

(continued)

7. Connect a computer to the TriStar if making adjustments with
PC software.

8. Replace the cover.

2.3 Installation Steps

The TriStar controller must be installed properly and in accordance with the
local and national electrical codes. It is also important that the installation be
done safely, correctly and completely to realize all the benefits that the TriStar
can provide for your solar system.

Refer to Sections 4.0 and 9.0 for information about the TriStar’s standard
battery charging programs and general charging needs for different
battery types. Refer to Section 5.0 for load control information, and

NOTE: When mounting the TriStar, make sure the air flow around the

controller and heat sink is not obstructed. There should be open space above
and below the heat sink, and at least 75 mm (3 inches) clearance around the
heat sink to allow free air flow for cooling.

REMARQUE : Lors du montage du TriStar, assurez-vous que l’écoulement
d’air autour du contrôleur et du puits de chaleur n’est pas obstrué. Un espace
doit se trouver au-dessus et en dessous du puits de chaleur et un
dégagement de 75 mm (3 po) doit exister autour du puits de chaleur pour
permettre l’écoulement de l’air à des fins de refroidissement.

Before starting the installation, place the TriStar on the wall where it will be
mounted and determine where the wires will enter the controller (bottom, side,
back). Remove the appropriate knockouts before mounting the controller. The
knockouts are sized for 1 inch and 1.25 inch conduit.

Section 6.0 for diversion.

14 TRISTAR INSTALLATION 15 MORNINGSTAR CORPORATION

REMARQUE : Les instructions ci-dessous concernent la charge de batteries

(10.25)

(5.00)

solaires. Reportez-vous à l’Annexe 1 pour les réglages du commutateur DIP
de contrôle de charge et à l’Annexe 2 pour les réglages du commutateur DIP
de contrôle de charge de diversion.

The DIP switches are located behind the negative power terminals. Each
switch is numbered. The solar battery charging functions that can be adjusted
with the DIP switches follow:

DIPON

260.4

189.7
(7.47)

15.2

(0.60)

ON

OFF

Control Mode/
Battery Charging (1)

1 2 3 4 5 6 7 8

System Voltage (2,3)

45.7

(1.80)

25.4

(1.00)

mm

(inches)

Figure 2.3 - Step 2 Mounting Dimensions

Step 2 - Mounting (continued)

Refer to Figure 2.3.

Use the template provided in the shipping carton for

41.9

(1.65)

(0.66)

85.1

(3.35)

16.8

110.5
(4.35)

127.0

Figure 2.4 - Step 3 DIP Switch Functions

As shown in the diagram, all the positions are in the “OFF” position except
switch numbers 7 and 8, which are in the “ON” position.

NOTE: The DIP switches should be changed only when there is no power
to the controller. Turn off disconnect switches and remove all power to the
controller before changing a DIP switch. A fault will be indicated if a switch
is changed while the controller is powered.

Battery Charging

Algorithm (4,5,6

Battery Equalization (7)

Noise Reduction (8)

locating the mounting holes and for stripping the wires. Use two of the #10
screws provided for the two keyhole slots. Leave the screw heads protruding
enough to lock inside the keyhole slots (about 3.8 mm / 0.150 inch). Mount the
controller and pull it down to lock the screws into the slots. Use the remaining
two screws to fasten the controller to the wall.

Provide for strain relief for the bottom knockouts if conduit will not be used.
Avoid excessive pulling forces on the terminals from the wires.

Step 3 - Adjust the DIP Switches

An 8-position DIP switch is used to set-up the controller for its intended use.
All major functions can be set with the DIP switches.

See Section 7.0 for

additional custom settings using PC software.

NOTE: The instructions below are for solar battery charging.
Refer to Appendix 1 for Load Control DIP switch settings, and Appendix 2 for

REMARQUE : Les commutateurs DIP ne doivent être remplacés que si le
contrôleur est hors tension. Mettez tous les interrupteurs sur arrêt et mettez le
contrôleur hors tension avant de changer un commutateur DIP. Une panne
sera indiquée en cas de changement d’un commutateur alors que le
contrôleur est sous tension.

CAUTION: The TriStar is shipped with all the switches in the “OFF” position.
Each switch position must be confirmed during installation. A wrong setting
could cause damage to the battery or other system components.

PRUDENCE : Le TriStar est expédié avec tous les interrupteurs en position
« ARRÊT ». La position de chaque interrupteur doit être confirmée pendant
l’installation. Un mauvais réglage peut endommager la batterie ou d’autres
composants du système.

Diversion Charge Control DIP switch settings.

16 TRISTAR INSTALLATION 17 MORNINGSTAR CORPORATION

)

2.0

The DIP switch settings described below are for Solar Battery Charging only.

1 2345678

DIPON

ON

OFF

Load and Diversion switch settings can be found in Appendixes 1 and 2.
The DIP switches are shipped in the OFF position. With the switches in the

OFF position, the following functions are present:
Switch Function

1 Battery charge mode
2, 3 Auto voltage select
4, 5, 6 Lowest battery charging voltage
7 Manual equalization
8 Normal PWM charging mode

To configure your TriStar for the battery charging and control you require,
follow the DIP switch adjustments described below. To change a switch from
OFF to ON, slide the switch up toward the top of the controller. Make sure
each switch is fully in the ON or OFF position.

DIP Switch Number 1 - Control Mode: Solar Battery Charging

Control Switch 1
Charging Off
Load On

DIP Switches Number 2,3 - System Voltage:

Voltage Switch 2 Switch 3

Auto Off Off
12 Off On
24 On Off
48 On On

ON

OFF

Auto Select

1 2 3 4 5 6 7 8

12 Volts

1 2 3 4 5 6 7 8

DIPON

24 Volts

1 2 3 4 5 6 7 8

DIPON

48 Volts

1 2 3 4 5 6 7 8

Figure 2.6 - 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 battery to indicate a lower system voltage.

The DIP switch selectable voltages are for 12V, 24V or 48V lead-acid
batteries. Although the “auto voltage” selection is very dependable, it is

2.0

DIPON

DIPON

recommended to use the DIP switches to secure the correct system voltage.

DIP Switches Number 4,5,6 - Battery Charging Algorithm:

Figure 2.5 - Step 3 DIP Switch #1

Battery Type PWM Switch 4 Switch 5 Switch 6

1 14.0 Off Off Off
For the Solar Battery Charging control mode, leave the DIP switch in the
OFF position as shown.

2 14.15 Off Off On

3 14.35 Off On Off

4 14.4 Off On On

5 14.6 On Off Off

6 14.8 On Off On

7 15.0 On On Off

8 Custom On On On

ON

PWM 14.0V

OFF

PWM 14.15V

PWM 14.35V

PWM 14.4V

18 TRISTAR INSTALLATION 19 MORNINGSTAR CORPORATION

Figure 2.7 - Step 3 DIP Switch # 4,5,6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

DIPON

PWM 14.6V

1 2 3 4 5 6 7 8

DIPON

PWM 14.8V

1 2 3 4 5 6 7 8

DIPON

PWM 15.0V

1 2 3 4 5 6 7 8

DIPON

Custom

1 2 3 4 5 6 7 8

DIPON

DIPON

DIPON

DIPON