Morningstar TS-MPPT-60-600V-48-DB-TR, TS-MPPT-60-600V-48-DB-TR-GFPD Maintance Manual
TM
TriStar MPPT
600V
with
Off-grid / Grid-tie
Transfer Switch
Solar Charging System Controller
Installation, Operation and Maintenance Man
For the most recent manual revisions, see the version at:
www.morningstarcorp.com
ual
Solar Battery Charger with
TrakStarTM Maximum Power Point Tracking Technology
MAXIMUM POWER POINT TRACKING
www.morningstarcorp.com
MODELS
TS-MPPT-60-600V-48-DB-TR
TS-MPPT-60-600V-48-DB-TR-GFPD
36.40
925 ]
35.57
[ 904 ]
8.70
[ 221 ]
1.35
[ 34 ]
5.25
[ 133 ]
6.10
[ 155 ]
2.47
[ 63
]
11.60
[ 295 ]
9.39
[ 239 ]
1.10
[
28 ]
6.50
[ 165 ]
3.25
[ 83 ]
4.40
[
112]
1.40
[
36 ]
3.30
[
84 ]
1.00
[ 25 ]
14.17
[ 360 ]
1.15
[ 29 ]
6.80
[
173]
12.80
[ 325 ]
14.17
[ 360 ]
1.15
[
29 ]
4.50
[ 114]
12.80
[ 325 ]
.90
[ 23 ]
1.30
[
33 ]
.80
[
20 ]
1.30
[
33 ]
2.02
[ 51 ]
1.04
[
26 ]
.90
[
23 ]
1.30
[
33 ]
1.04
[ 26 ]
2.02
[ 51 ]
1.30
[ 33 ]
.90
[
23 ]
12 PLACES
O 0.21 [ 5 ]
2.60
[
66 ]
14.03
[ 356 ]
14.17
[ 360 ]
1.04
[ 26 ]
3.06
[ 78 ]
1.35
[ 34 ]
2.83
[ 72 ]
3.83
[ 97 ]
4.83
[ 123 ]
5.83
[ 148 ]
7.35
[ 187 ]
.78
[ 20 ]
1.30
[ 33 ]
2.82
[ 72 ]
5.86
[ 149 ]
3.34
[ 85 ]
3.40
[
86 ]
6.20
[ 157 ]
Dimensions in inches [millimeters] TABLE OF CONTENTS
1.0 Important Safety Instructions 4
2.0 Getting Started 10
2.1 Overview 10
2.2 Regulatory Information 10
2.3 Versions 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 Audible Warnings 52
4.7 Protections, Faults & Alarms
54
5.0 Networking and Communication 57
5.1 Introduction 57
5.2 Morningstar MeterBusTM 58
5.3 Serial RS-232 59
5.4 EIA-485 (formerly RS-485) 61
5.5 Ethernet 62
6.0 Testing and Troubleshooting 66
7.0 Maintenance and Service 69
7.1 Important Safety Instructions 69
7.2 Maintenance Schedule 75
8.0 Warranty and Policies 76
9.0 Technical Specications 79
10.0 Appendix 85
11.0 Certications 89
5 TriStar MPPT-600V-TR Operator's Manual4 Important Safety Instructions
Informations de Sécurité
• Lisez toutes les instructions et les avertissements gurant dans le manuel avant de commencer l’installation.
• Le TS-MPPT-600V-TR 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 TS-MPPT-600V-TR.
• Le TS-MPPT-600V-TR 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 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 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.
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 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.
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 TS-MPPT-600V-TR. 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
TS-MPPT-600V-TR.
• There are no fuses or disconnects inside the TS-MPPT-600V-TR Do not attempt to repair.
1.0 Important Safety Instructions
7 TriStar MPPT-600V-TR Operator's Manual
6
Important Safety Instructions
• 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 TS-MPPT-600V-TR 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 TS-MPPT-600V-TR (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 TS-MPPT-600V-TR doivent être
protégées avec un conduit ou une bague.
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.
AVE RTISSEMENT: 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: When replacing batteries, proper specied 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.
• This charge controller is to be connected to DC circuits only. These DC connections are identied
by the symbol below:
Direct Current Symbol
The TS-MPPT-600V-TR controller must be installed by a qualied 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.
The TS-MPPT-600V-TR negative power terminals are common, and must be grounded as instructions, local codes, and regulations require.
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
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 TS-MPPT-600V-TR à l’intérieur. Empêchez l’exposition aux éléments et la pénétration
d’eau dans le contrôleur.
• Installez le TS-MPPT-600V-TR 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:
9 TriStar MPPT-600V-TR Operator's Manual
8
Important Safety Instructions
• 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 600V.
• 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
certain there is enough ventilation to
release the gases.
• Never smoke in the battery area.
• If battery acid comes into contact with the skin, wash with
soap and water. If the acid contacts the
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 *).
• Lisez attentivement les instructions du fabricant de la batterie avant d’installer / connexion à ou
retrait des batteries du TriStar MPPT 600V.
• 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 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.
About this Manual
This manual provides detailed installation and usage instructions for the TS-MPPT-600V-TR con-
troller. Only qualied electricians and technicians who are familiar with solar system design and
wiring practices should install the TS-MPPT-600V-TR. The usage information in this manual is
intended for the system owner/operator.
11 TriStar MPPT-600V-TR Operator's Manual10 Getting Started
Getting Started2.0
2.1 Overview
Thank you for selecting the TS-MPPT-600V-TR solar charge controller. Both models are
specialized components designed for use in grid-tie / off-grid systems. These products feature a
transfer switch which allows the user to toggle connections between a grid-tie inverter and
battery bank storage. The diagram below shows the basic dual-mode functionality of the
product.
SOLAR
ARRAY
Input (+) and
(-) Wires
TS-600V-MPPT-TR
Battery
Disconnect
Main Input
Disconnect
Battery
Bank
Grid-tie
Inverter
Transfer
Switch
GFPD
PV and battery
(+) and (-)
connections
PV and battery
(+) and (-)
connections
The TS-MPPT-600V-TR with TrakStarTM MPPT Technology 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 TS-MPPT-600V-TR 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 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 qualied technician according to the
electrical rules of the country in which the product will be installed.
TS-MPPT-600V-TR controllers comply with the following EMC standards:
• Immunity: EN61000-6-2: 2005
• Emissions: EN55022:2 2007 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 TS-MPPT-600V-TR 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 TS-MPPT-600V-TR 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.
13 TriStar MPPT-600V-TR Operator's Manual
12
Getting Started
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:
• Re-orient 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-003 du Canada.
2.3 Versions and Ratings
There are two versions of TS-MPPT-600V-TR controller:
TS-MPPT-60-600V-48-DB-TR
• enhanced wiring Disconnect Box (DB) with battery disconnect breaker
• maximum 60 amps continuous battery current
• 48 Volt DC systems
• Maximum 600 volt DC solar input voltage
• RS-232, EIA-485, MeterBus
TM
, and Ethernet communication ports
TS-MPPT-60-600V-48-DB-TR-GFPD
• enhanced wiring Disconnect Box (DB) with battery disconnect breaker
• maximum 60 amps continuous battery current
• 48 Volt DC systems
• maximum 600 volt DC solar input voltage
• RS-232, EIA-485, MeterBus
TM
, and Ethernet communication ports
• includes the GFPD-600V ground-fault protection device
15 TriStar MPPT-600V-TR Operator's Manual
14
Getting Started
2.4 Features
The features of the TS-MPPT-600V-TR-GFPD model are shown below in Figure 2-1. An
explanation of each feature follows.
Figure 2-1. TS-MPPT-600V-TR-GFPD Features
TS-MPPT-60-600V-48-DB-TR Box
1 - Heatsink
Aluminum heatsink to dissipate controller heat (the TS-MPPT-600V-TR is 100% passively cooled
for reliability)
2 - Battery Negative Power Terminal
Power connection for (-) battery cable termination
3 - Battery Positive Power Terminal (red)
Power connection for (+) battery cable termination
4 - Settings Switches
Eight (8) settings switches to congure operation of the TS-MPPT-600V-TR-DB
5 - MeterBus
TM
Port
RJ-11 socket for Morningstar MeterBusTM network connections
6 - Ethernet Port
RJ-45 socket for LAN/internet connections
7 - Serial RS-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 out to Grid-Tie Inverter Solar Input
14 - Transfer Switch
Controls grid-tie and battery charging modes
15 - LED Indicators
Show battery state-of-charge (SOC) and controller fault conditions
16 - Remote Temperature Sensor Terminals
Connection point for a Morningstar RTS to remotely monitor battery temperature
17. Push-button Switch
Manually reset from an error or fault. Start/stop a manual equalization.
18 - Battery Voltage Sense Terminals
Terminals for battery voltage input provide accurate battery voltage measurement
2
3
4
5
6
7
8
10
20
19
9
18
17
16
15
11
14
13
12
21
22
23
24
25
29
28
27
26
1
17 TriStar MPPT-600V-TR Operator's Manual
16
Getting Started
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 TS-MPPT-600V-TR controller. DIN rail compatible. See section 5.2 for more
details.
Relay Driver (RD-1)
The Relay DriverTM accessory enables the TS-MPPT-600V-TR 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 TS-MPPT-600V-TR controllers to a PC or to other serial devices using the
EIA-485 adapter. The adapter converts an RS-232 serial interface to EIA-485 compliant bus
signals. An LED shows network activity and errors. DIN rail compatible.
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.
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 assembly
22 - Ganged Ground-fault Breakers
(+) and (-) leg ground-fault interruption breakers
23 - (+) and (-) Solar Breaker Post Connections [(pre-wired),(underside)]
Connection points for (+) and (-) solar wires
24 - Solar Wiring Aperture
Sensing opening for GFPD control
25 - Auxilliary DIN Rail Mount
Available for DIN mountable equipment
26 - Grounding Terminal Block
A chassis terminal for system grounding
27 - Test / Reset Button
Performs testing and reset functions
28 - Bi-Color LED
Indicates various fault and alarm conditions
29 - GFPD Control and Power Terminals
Terminal connections for GFPD signals and power.
2.5 Optional Accessories
The accessories described below are available for purchase separately from your authorized
Morningstar dealer. Please see the individual product manuals for installation and operation
details.
TriStar Meter 2-600V; TriStar Remote Meter 2 (Models: TS-M-2-600V; TSRM-2)
The TS-M-2-600V mounts directly on the TS-MPPT-600V-TR controller, replacing the blank
meter cover on the wiring box lid. The TS-RM-2 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.
TriStar meters connect to the RJ- 11 MeterBus
TM
port on the TS-MPPT-600V-TR. One (1) meter
can display select full system information when multiple TS-MPPT-600V-TR or other TriStar controllers are connected via a MeterBus
TM
network.
19 TriStar MPPT-600V-TR Operator's Manual18 Installation
3.1 General Information
WARNING: Equipment Damage or Risk of Explosion
Never install the TS-MPPT-600V-TR in an enclosure with vented/ooded batteries.
Battery fumes are ammable and will corrode and destroy the TS-MPPT-600V-TR
circuits.
!
CAUTION: Equipment Damage
When installing the TS-MPPT-600V-TR in an enclosure, ensure sufcient ventilation.
Installation in a sealed enclosure will lead to over-heating and a decreased product
lifetime.
AVERTISSEMENT: Endommagement de l’équipement ou risque d’explosion
N’installez jamais le TS-MPPT-600V-TR dans une enceinte avec des batteries à évent/à
électrolyte liquide. Les vapeurs des batteries sont inammables et corroderont et
détruiront les circuits du TS-MPPT-600V-TR.
!
PRUDENCE: Endommagement de l’équipement
Assurez une ventilation sufsante en cas d’installation du TS-MPPT-600V-TR dans une
enceinte. L’installation dans une enceinte hermétique entraîne une surchauffe et une
réduction de la durée de vie du produit.
WARNING: Installation must comply with all US National Electrical Code and Canadian Electrical Code
requirments. Breakers and fuses may require lower ratings than referenced below, so as not to exceed
any specic wire ampacity.
Avertissement : Installation doit être conforme aux tous les États-Unis National Electrical Code et
Code canadien d'électricité requirments. Disjoncteurs et fusibles peuvent nécessiter des cotes
inférieures que référencé ci-dessous, de manière à ne pas dépasser n'importe quel fils particulier
admissible.
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 FIRST before beginning installation.
The installation instructions are for installation of a negative grounded system. U.S 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.
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.
Stranded wires to be connected to the TS-MPPT-600V-TR 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.
Installation3.0
Recommended Tools:
• Wire strippers
• Wire cutters
• #2 & #0 Phillips screwdriver
• slotted screwdrivers
• Pliers
• Drill3/32” (2.5 mm) drill bit
• Level
• hack saw (cutting conduit)
3.2 Wiring Zones
The 600V solar circuits must be separated from the low voltage battery circuits and
communication wiring within the wiring box. Figure 3-1 below shows the high voltage and low
voltage zones (shaded) within the wiring box. There is overlap in the zones as pictured because
the removable wiring divider separates the high voltage solar wiring and low voltage wiring. Solar
high voltage wiring should be routed below the removable wiring divider. The yellow Solar
Terminal Bridge must be properly tted in place before making the solar power terminal
connections.
The battery wiring and all communication cables must only be routed within the low voltage
wiring zone. After the solar wiring is installed, the wiring divider should be secured in place, and
the battery cables routed above the divider. Detailed installation steps are provided in the
following sections.
NOTE: If ALL eld wiring, including communications cable, is rated for 600V, wiring zone separation is
not required. In this case, it may be more convenient to remove the high-low voltage wiring box divider,
and terminate conduit that contains mixed voltage conductors at one point.
REMARQUE: Si tout câblage, y compris câble de communication, est évalué à 600V, câblage zone
séparation est non requis. Dans ce cas, il peut être plus pratique d'enlever le diviseur de boîte câblage de
tension haut/bas, et n des conduits contenant des conducteurs mixtes de tension à un moment donné.
21 TriStar MPPT-600V-TR Operator's Manual
20
Installation
High and Low Voltage Wiring Positions - TS-MPPT-600V-TR
Figure 3-1. TS-MPPT-600V-TR / GFPD high and low voltage wiring zones (shaded areas)
600V wiring below
the removable
Wiring Divider
(divider removed)
Low voltage wiring
above the Wiring
Divider
(divider in place)
3.3 Conduit Knock-Outs and Wire Routing
Knock-outs are provided for routing cables through conduit or wire glands. Table 3-1 details the
knockout sizes and quantity 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 between TS-MPPT-600V-TR controllers that are mounted side-by-side without the need for exter-
nal conduit tubing. Table 3-1 identies the pass-through knock-outs which may be used for this
purpose. Figure 3-6 shows the routing of the high voltage and low voltage wiring paths.
3
8
7
10
4
9
2
2
6
5
5
1
1
1
3
6
11
Figure 3-2. Knock-outs, left , right and back views
23 TriStar MPPT-600V-TR Operator's Manual
22
Installation
3
1
4
Figure 3-3. Knock-outs, bottom view
Item
Quantity Trade Size Hole Dimension
Circuit(s)
1 2 (Concentric) 1” & 3/4” 1.36“ (34.5 mm) / 1.09” (27.8 mm) Solar (high voltage)
2 2 (Concentric) 1-1/4“ & 1“ 1.72” (43.7 mm) / 1.36“ (34.5 mm) Battery (low voltage)
3 2 (Concentric) 1-1/4" & 1" 1.72” (43.7 mm) / 1.36“ (34.5 mm) Solar (high voltage)
4 11 1/2” or M20 7/8” (22.2 mm) Solar (high voltage)
5 1 1/2” or M20 7/8” (22.2 mm) Communication
6 1 3/4” 1.09" (27.8 mm) Communication
7 4 3/4" Solar (high voltage)
8 2 1” 1.36“ (34.5 mm) Battery (low voltage)
9 3 1/2” or M20 0.88” (22.2 mm) Battery
10 2 1/2” or M20 0.88” (22.2 mm) Solar
11 2 3/4” 1.09” (27.8 mm) Solar (high voltage)
** Solar connector mounting hole diameters vary. Wieland Solar DC connectors recommended.
Table 3-1. Knock-out sizes
3.4 Controller Installation
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 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 600V.
Use a #2 Phillips screw driver to remove the four (4) screws that secure the wiring box cover as
shown in gure 3-4 below.
Figure 3-4. Remove the wiring box cover.
Step 2 - Remove the Wiring Divider
The wiring divider separates the solar high voltage wiring from the low voltage battery and
communication circuits - see Figure 3-5. The divider is secured with only one screw.
1. Use a #2 Philips screw driver to remove the screw.
2. Lift and tilt the divider towards the bottom of the unit as shown in Figure 3-5.
3. Carefully move the GFPD power wires outside of the box.
4. Lift the divider out of the wiring box and set the divider and screw aside. The divider
must be replaced in a later step.
!
!
25 TriStar MPPT-600V-TR Operator's Manual
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Installation
1
2
3
4
Figure 3-5. Remove the Wiring Divider.
Step 3 - Remove the Knock-Outs
Plan the routing of each conductor that will connect to the TS-MPPT-600V-TR before removing
any knock-outs. The 1/2” (M20) knock-outs are ideal for routing network cables, which must be
placed in separate conduit.
Use a at head screwdriver to remove the necessary knock-outs. A hammer may also be
required to apply extra force. Refer to Section 3.2 for detailed knockout information.
WARNING: Shock Hazard
Always use bushings, connectors, clamp connectors, or wire glands in the knock-out 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.
WARNING: Shock Hazard
Never route network cables in the same conduit as the power conductors.
AVERTISSEMENT: Risque de décharge électrique
N’acheminez jamais les câbles réseau dans le même conduit que les conducteurs
d’alimentation.
Step 4 - Mounting to a Vertical Surface
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 TS-MPPT-600V-TR 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 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 pendant le fonctionnement.
1. Attach the mounting hanger to the bottom of the TS-MPPT-600V-TR with the M6 screw
provided as shown in gure 3-6.
2. Place the TS-MPPT-600V-TR on a vertical surface protected from direct sun, high
temperatures, and water. The TS-MPPT-600V-TR requires at least 6” (150 mm) of
clearance above and below and at least 1” (25 mm) between the controller and adjacent
walls for proper air ow as shown in gure 3-7 below.
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.
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 TS-MPPT-600V-TR with the screw head. Slide the
TS-MPPT-600V-TR down over the keyhole.
Check for vertical plumb with a level.
7. Mark four (4) mounting hole locations in the wiring box, and two (2) in the GFPD box,
if applicable.
8. Remove the controller and drill 3/32” (2.5 mm) holes at the drill marks.
9. Carefully align the keyhole on the TS-MPPT-600V-TR with the screw head. Slide the
TS-MPPT-600V-TR down over the keyhole. The pre-drilled pilot holes should align
with the mounting holes in the wiring box.
10. Secure the controller with four (4), for DB model, #10 mounting screws.
11. Tighten the keyhole screw.
!
27 TriStar MPPT-600V-TR Operator's Manual
26
Installation
Figure 3-6. Attaching the mounting hanger
Figure 3-7. Allowing for passive cooling
M6 Screw
Mounting Hanger
AT LEAST
1” (25 mm)
AT LEAST
1” (25 mm)
COOL AIR
WARM AIR
AT LEAST
6” (150 mm)
Step 5 - Network Connections
Network connections allow the TS-MPPT-600V-TR to communicate with other controllers or
computers. A network can be as simple as one controller and one PC, or as complex as dozens
of controllers monitored via the internet. Review section 5.0 for more information about
networking and the connection(s) required for your system.
WARNING: Shock Hazard
Only route network cables in the same conduit as the photovoltaic power conductors if all
conductors are rated for 600V.
WARNING: Shock Hazard
Only use 300 volt or 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 this time. Access to the
network ports is easier before the battery power cables are attached. The ports are located inside
the conduit wiring box on the lower circuit board as shown in gure 3-8.
EIA-485 (4 - position)
RJ-45 Ethernet
RJ-11 MeterBus
TM
RS-232 (9 - pin female)
Figure 3-8. TS-MPPT-600V-TR network port locations
EIA-485 Connection
The four (4) position EIA-485 connector on the TriStar MPPT must be removed to access the
terminal screws. Remove the socket connector by rmly grasping the connector body and pulling
away from the circuit board as shown in gure 3-9.
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