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Comprehensive installation and operation instructions

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Diagram showing concept of Tristar MPPT600V-TR in grounded and ungrounded system applications

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Remote Temperature Sensor Datasheet

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Tristar Digital Meter – 2 Manual in English

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Ground Fault Protection Device Datasheet

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TriStar Meter-2 & TriStar Meter-2-600V and TriStar Remote Meter-2 Datasheet

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485 Network with Multiple TriStar and TriStar MPPT units, configured to provide communication redundancy.

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A diagram showing an effective way to implement load control using the Morningstar Relay Driver accessory module. Best used in systems that do not utilize controllers with built-in load control circuitry.

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This diagram shows an example system including a TriStar MPPT performing charging functionality and a TriStar performing Load Control functionality.

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This diagram shows an example system including a TriStar MPPT 60 performing charging functionality and a TriStar performing Load Control functionality. An EIA-485 network is used to enable Ethernet communications with the TriStar Load Controller.

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This document provides details regarding configuration of the TriStar MPPT 60, along with additional Morningstar devices, for bridged MODBUS/TCP communication on an EIA-485 network.

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Networking instructions for connecting the Ethernet enabled TriStar MPPT controller to your Local Area Network (LAN).

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This document discusses solar module sizing, power ratings and answers some of the more frequently asked questions in order to help make sense of the many options available on the market.

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A diagram shows how to correctly wire charge controllers to a battery bank comprised of multiple parallel strings. Correct wiring is important to ensure even and distributed charging of the entire bank.

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A diagram showing two SunSaver controllers shows how to properly parallel multiple Morningstar controllers into the same battery system. The concepts shown are applicable to all Morningstar controller models.

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A diagram shows how to properly wire a charge controller and an inverter into the same battery-based PV system.

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A white paper discussing the advantages and disadvantages of PWM and MPPT charge controller technologies. Sizing, environmental, and cost factors are discussed.

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There is often a need to charge two or more isolated batteries with the same off-grid solar system. Morningstars SunSaver-Duo charge controller is designed to charge 2 isolated battery banks with an adjustable charging priority. We recommend the use of this controller for isolated battery bank applications.

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Wiring diagram and procedures when using the TriStar, TriStar-MPPT, ProStar, or ProStar MPPT controllers in positive ground systems.

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Complete list of register locations, variable descriptions and scaling for Modbus RTU communications.

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Tristar MPPT600V Fault and Alarm Code and possible cause listing

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A comprehensive guide to communication with Morningstar products.
Topics covered include:

• MeterBus networks
• Serial RS-232 and EIA-485 networks
• Ethernet, HTTP, web interfaces
• Related hardware and cables

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Comprehensive installation and operation manual

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Yes. There can be as many Morningstar controllers as required in parallel on the same battery bank. For best performance, set each controller to as close a charge setting as possible. Since the controllers will not have direct communication with each other, it is not unusual to see the controllers transition between charging stages at different times. This is generally not a concern.

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Yes, the optional RTS is required for the temperature compensation feature. If an RTS in not used, the TriStar or TriStar MPPt will not compensate charging setpoints for temperature.

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When two conductors (a wire and screw terminal for instance) are mated, there is a resistance at that connection. Usually this contact resistance is very low and poses no threat. However, when connections become loose, oxidation builds on the surfaces, or corrosion accumulates, the resistance at the connection can increase to a dangerous level.

When current passes through resistance, power is dissipated in the form of heat. If the value of the resistance goes up, so does the power dissipated (for the same amount of current). When a connection has high resistance, the heat generated at the connection can melt surrounding material such as plastics and actually catch fire.

Resistive connections can occur on any electronic device that carries significant amounts of power. It is important to periodically check the tightness of the connections and inspect for corrosion as suggested in the Maintenance section of the Operator’s Manual. Along with periodically checking the connections, dielectric grease can be applied to the terminals to avoid corrosion build-up on the conductor surfaces. Mobile installations tend to be the most susceptible to developing resisitve connections because motion works cables loose from their terminals, however, resistive connections can occur on stationary installations as well.

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A controller may become inaccessible over a network if a static IP address incompatible with the network has been programmed into the controller. The only way to reset an IP address of a controller, or to re-enable DHCP, is to directly connect it to a PC. Direct connections include Ethernet (direct wire, NO router, etc.) or Modbus (serial interface).

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A link to the agent Management Information Base file (*.MIB) is available for download directly from the controller. Access the TriStar MPPT Live View Network Settings page and use the MIB download link.

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All Morningstar controllers will automatically prevent reverse discharge of the battery back through the solar array during the night. No external diodes on the input of the controller are required.

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Other charging sources can be used in parallel with the Morningstar charge controller; you do not need to isolate the controller from the battery. For best performance when using other charging sources, ensure the charging source and Morningstar controller are set to charge to the same (or close) voltage. If the supplemental charging source is set to a higher charging voltage than the Morningstar controller, the Morningstar controller may go into a fault state temporarily when the battery voltage rises higher than the controller’s setpoint. The controller will automatically recover from this state when the battery voltage drops to a lower level.

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If no input source (solar) is connected to the charge controller, but there are other charging sources connected to the batteries, charge controller may still show a Green Flashing LED (indicating that the controller is in the absorption charging stage). The Green Flashing LED may appear on the Morningstar controller if the battery voltage is at or above the controller’s Absorption charging voltage setting. Although the controller is not delivering power to the batteries (because there is no input source present), the indication still appears. This is not an indication of controller malfunction.

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Yes, on select Morningstar controllers. The MSView PC software will provide logging capability through the serial or Ethernet port. Additionally, a number of commercial dataloggers and PLCs support the Modbus protocol.

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Yes, select Morningstar controllers can accept custom charging setpoints. Using our free MSView software, you can configure many of the setpoints and parameters for charging. Please refer to the controller datasheet and manual for more information

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If you are having problems communicating with a Morningstar product using a serial connection, try the following:

1. Make sure that the unit is powered with a battery or power supply. The unit cannot communicate without power.

2. Verify that the serial cable is not a Null Modem or cross-over cable.

3. Verify that no other programs or managers are using the same serial port.

4. Check the serial cable for continuity using a multimeter. The cable should have continuity from Pin1<->Pin1, Pin2<->Pin2,… If possible, try another cable.

5. Shut down and restart the PC. Reattempt connection.

6. Try another PC

For products that require the PC MeterBus Serial Adapter (Model: MSC), check the RJ-11 telephone cable. If possible, try another cable. It has been reported that some USB to Serial cables will not work with the MSC because the RS-232 output signal voltages are below the RS-232 electrical specification.

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We supply PC software free of charge (called MSView). It is available for download on our website. Sorry, Apple Mac is not supported.

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Direct from the FAQ at http://www.modbus.org :

MODBUS® Protocol is a messaging structure developed by Modicon in 1979, used to establish master-slave/client-server communication between intelligent devices. It is a de facto standard, truly open and the most widely used network protocol in the industrial manufacturing environment. It is literally implemented by hundreds of vendors on thousands of different devices in order to transfer discrete/analog I/O and register data between control devices. It’s really a lingua franca or common denominator between different manufacturers. One report called it the “de facto standard in multi-vendor integration”.

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RS-232 serial cables can be found at just about any computer retail store. In most cases, such as mating the TriStar or SunSaver Duo to a PC, you will require a cable with one male and one female connection. Linking a PC with the controller will require a straight-through serial cable (NOT a NULL Modem cable).

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MSView contains a built-in Help File (accessible from the Help menu -> Help Topics) which provides detailed information about using the software to connect to Morningstar devices, program custom settings, view and/or log real-time data, and evaluate system performance.

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The SunSaver MPPT and TriStar MPPT have several unidentified / numbered Alarm states. Numbered alarm information is as follows:

Alarm 19 = Power On Reset (the controller has recently been reset/rebooted)
Alarm 20 = LVD Condition (an LVD – Low Voltage Disconnect – event has occurred)
Alarm 21 = Log Timeout Alarm (the controller’s internal logger has not been able to write a log entry for the past 24hrs)

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This Tech Tip discusses the use of today’s 60 cell PV modules with Morningstar’s solar controllers. It explains why 60 cell modules are not well adapted for meeting the nominal array voltage requirements of PWM controllers. It also shows how Morningstar’s MPPT controllers can be used with great success at higher input voltages.

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If one or more DIP switches are changed while the controller/inverter is powered, the controller/inverter will display a DIP Switch Changed Fault (and the LEDs will begin to sequence). Changing DIP switches while the unit is operating will cause the unit to stop charging until the unit is reset. A reset can be performed by removing power from the device (so that all the LEDs go off) and then re-starting the unit. This procedure prevents the inadvertent changing of operational settings while the controller/inverter is active.

After the controller/inverter has been re-started, it will operate with the new DIP switch settings.

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The TriStar Meter family (TS-M, RS-RM, TS-M-2, TS-RM-2) cannot be used to change charging parameters. The TriStar Meters only display system data and provide basic user commands, such as resetting Amp-Hour counters and starting/stopping an Equalize charge.

For more information concerning the TriStar Meter family, please consult the respective TriStar Meter manual.

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The note below assumes the meter is powered and displaying text on the screen.

If a button(s) for any one of the following display models appears to stop working:

– TS-M / TS-RM
– TS-M-2 / TS-RM-2
– RM-1

there may be several explanations:

1) You have reached the end of a menu, and there are no more screens to display in that direction (e.g. if you go to the bottom of a menu and continue to push the DOWN arrow, nothing will happen)

2) If the backlight is OFF, the first button press will turn the backlight ON, but will not change the meter screen. E.g. if the backlight is OFF and you would like to move LEFT in the display, you must press LEFT twice – the first to turn the backlight ON, the second to move LEFT in the display). In brightly lit rooms or sunny conditions, it may be difficult to detect whether the backlight is ON or OFF.

3) The button contacts have become dirty. To clean the button contacts:

– Disconnect the meter cable from the back of the meter
– Remove the two screws on the back of the meter, holding the meter circuit board to the faceplate
– Wet a Q-tip or small paper towel with a small amount of alcohol
– Clean the 4 contact points on the circuit board and the contact point on each of the buttons

If the meter button(s) still do not function correctly after checking the points above, contact your Morningstar re-seller / dealer for warranty replacement.

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Measure the voltages directly at the TriStar terminals. Voltage drops due to line resistances can be significant.

Be sure the Battery Sense wires are not wired to the RTS(remote temperature sensor) terminals. Both terminals look similar and are easy to mix up.

Check for correct polarity at the Battery Sense connection.

Confirm your measurements with another multimeter.

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Most Morningstar controllers will take up to 5 minutes to realize that the solar input voltage is no longer present before transitioning into the ‘night’ state. The controller performs periodic day/nigh checks (about once every 5 minutes). Depending upon where the controller is in this cycle when the input is removed, it may take anywhere from 0-5min for the controller to turn off its Charging LED and go into the ‘night’ state.

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Morningstar controllers have been designed to mount vertically. This is the orientation in which the heatsinks are most effective. Mounting the controller horizontally will reduce its passive cooling efficiency, but the risk of overheating will be determined by the ambient temperature and the power level at which the controller will be operating.

All efforts should be made to mount the controller vertically.

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The TriStar an TriStar MPPT Operation Manuals provide detailed explanations concerning the flashing LED sequences that occur when a fault is present. The TriStar Digital Meter Installation and Operation Manual provides definitions for each of the faults and alarms displayed in the Diagnostics menu.

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Can I use a power source other than a PV panel to charge my batteries?

We do not recommend using a DC power supply with any of our PWM controllers. While they appear to be similar to PV modules in function, DC power supplies have considerably more output capacitance. Connecting a DC power supply to our PWM controllers may cause excessive heating and premature failure. MPPT controllers can be used for this purpose without issue. In addition, AC powered battery chargers are often the best option for systems requiring AC battery charging.

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Fuses, circuit breakers and disconnects should be included in your system. Refer to your local/national codes concerning requirements. The controller’s Operation Manual outlines NEC requirements for installations in the United States.

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How do I calculate the effect of temperature compensation on the regulation voltage?

Refer to the accompanying document download, which includes compensation curves for most Morningstar Controllers, or refer to temperature compensation coefficient in the specifications section of the Operator’s Manual.

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Yes, we recommend grounding the controller chassis per NEC requirements.

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Do Morningstar Controllers regulate according to SOC (State of Charge) calculations?

No. Morningstar Controllers regulate according to battery voltage setpoints. Because battery health and other factors affect charging over time, using voltage setpoints is a way to naturally track these changes and affords the user a complete understanding of the controllers operation. SOC calculations and algorithms may not be precise under all conditions and may leave the user with a “fuzzy” understanding of the workings of the unit.

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Can I charge separate battery banks with one Morningstar charge controller?

Yes.  Refer to the document, “Charging Isolated Battery Banks – 1 Controller”.

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The electrical negative is isolated from chassis ground.

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I sometimes hear a buzzing noise during charging. Is something wrong?

No. The buzzing sound is mechanical resonance created by the switching of current through the circuit board and solid-state devices. This is normal and not indicative of a problem.

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A higher voltage solar array (e.g. 24V nominal) can only be used with a lower voltage battery bank (e.g. 12V nominal) if the controller used is an MPPT controller.

PWM controllers CANNOT be used to charge a lower-voltage battery bank with a higher-voltage solar array. Please use an MPPT style controller if this is required.

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Our controllers are designed to charge lead-acid batteries which have different charging requirements than NiMh. Please DO NOT use our products with NiMh batteries, it is dangerous to do so.

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We allow up to 2 digital meters to be connected to a single TriStar. Any combination of local and remote meters is acceptable.

Note: due to power limitations on the bus, only one meter can have an illuminated backlight at any given time. A meter will turn off the other meter’s backlight if necessary before turning on its own backlight.

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The internal switches of a controller, called MOSFETs or power transistors, switch current on and off to control solar current and load current. Because these components are in the power path, the controller will no longer be able to switch current if they fail.

Power transistors can fail for the following reasons:

• Over-voltage: lightning or other high voltage transients on the PV power cables.
• Over-current: too much PV for the controller or a short in the PV line pulls too much currentout of the battery through the controller.
• Extreme temperatures during charging.
• A premature failure of the component. The transistors are solid state devices that are manufactured in huge volumes with extremely low failure rates. However, no electrical components are 100% defect free and can pass test and then fail after a short period of time.
• Old age

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Multiple TriStar controllers can be networked together over an EIA-485 network via their serial ports using the RSC-1 (RS-232 to EIA-485) converters. Each TriStar on the network will need a unique control address (Modbus ID) that can be programmed using the MSView PC software.  TriStar-MPPT controllers have integrated EIA-485 connections and do not require the use of an RSC-1 adapater.

Morningstar devices connected over an EIA-485 network can also be bridged through a TriStar-MPPT-60 or TriStar MPPT 600V controller for remote monitoring over an Ethernet connection.  Please refer to the Morningstar Communications Document and TriStar/TriStar-MPPT Bridging Redundancy Document for additional information.

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When large currents flow through the battery power cables, a voltage drop results due to resistance in the cables. Since the controller regulates the batteries according to battery voltage, it is important that the controller measure the voltage directly at the battery. The Battery Sense connection allows battery voltage measurement directly at the terminals because the sense lines carry very little current (hence, small-gauge wire) enabling accurate regulation.   Without the sense lines, the controller must use the battery power connections, which may be different than actual battery voltage. The Battery Sense connection is optional and is only needed when significant voltage drops exist on the battery power cables.

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Problem: When power is applied to the controller, the SOC LEDs do not perform the full start-up G-Y-R sequence, and stop on yellow (solid ON). The controller is not working.

Solution: This indicates that firmware is not properly loaded into the controller. Download the MSLoad firmware utility and the latest firmware. Follow the instructions to load new firmware into the controller. If unsuccessful, contact your authorized Morningstar dealer for service.

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Indicates a High Voltage Disconnect fault.

Possible causes:
1) wired past controller switches (bypassed the controller, system wiring error)
2) Sense connection problem
3) RTS connection problem
4) DIP Switch system Voltage wrong
5) Custom settings: setpoints too low (in load control mode, HVD only enabled in custom)
6) Other charging sources in the system. Other charging sources in the system may be charging the battery above the controller’s regulation set-point, causing the high voltage indication. The indication will clear when battery voltage has returned to normal.

Use the troubleshooting flow diagram for system diagnosis.

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Red & Yellow – Green & Yellow sequencing LEDs indicate one of the following faults:

• Remote Temp Sensor Fault
• Battery Sense Fault

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Electrical negative is isolated from chassis ground in the TriStar and TriStar MPPT family of controllers. Morningstar recommends earth grounding the chassis per NEC guidelines. See the installation section in the Owner’s Manual for more details.

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If voltage and/or current measurements do not match the values reported on the TriStar meter (or values reported to MSView) check the following:

• Measure the voltages directly at the TriStar terminals. Voltage drops due to line resistances can be significant.

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TriStar state of charge (SOC) LED transitions are based on battery voltage setpoints, and provide only an approximation of the true SOC of the battery. A true SOC calculation is not performed because the TriStar does not have load current information (current drawn out of the battery). A TriStar in charge control mode (or a TriStar MPPT) can only measure current into the battery from the solar panels.

The LEDs will however provide a relative indication of how your system is performing. e.g.:

“Each day I charge to Green. At dusk it settles to Grn-Yel, by morning I’m at Yel-Red”

which may help detect problems if the LED behavior changes drastically. (charge all day and it doesn’t get out of red)

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Here’s a brief explanation on how to calculate the temperature compensated adjustments our controllers make to their charging voltages based on the ambient temperature changes.

The charging voltages listed in the controller operator’s manual are specified at a 25C standard test condition ambient temperature with a -.030V (@ 12V battery) adjustment per degree C change in temperature above or below the 25C reference. The (-) in front of the .030V indicates that voltage adjustment is inverse to the change in temperature. In other words, if the temperature increases above 25C, the controller decreases it’s charging voltage by -.030V per degree C rise above 25C and vice versa. An accurate measurement of the ambient temperature is required for calculating the the controller’s temperature compensated adjustment.

Example:

An ambient temperature of 35C = +10C increase above the 25C base temp = 10 x -.030V compensated adjustment = temperature compensated -.300V decrease in charging voltage.
Therefore, a 14.4V charging voltage specified in the manual @ 25C would be reduced to 14.1V @ 35C or increased to 14.7V @ 15C.

The compensation rate is doubled to .060V/C for 24Vnominal battery systems and quadrupled to .120V/C for 48V nominal battery systems.

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MSLoad is a PC software utility used to program new product firmware into Morningstar products that support firmware updates.

Instructions

• Download MSLoad
• Download the latest product firmware
• Unzip MSLoad
• View MSLoad README

Products supported

• Relay Driver
• SunSaver MPPT
• ProStar MPPT
• TriStar
• TriStar MPPT
• TriStar MPPT 600V
• TriStar Digital Meter
• TriStar Remote Meter
• TriStar Digital Meter 2
• TriStar Remote Meter 2

System Requirements

• Windows 95 or later
• x386 or later PC

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MSView is a PC software utility that allows a PC to connect to supported Morningstar products. It provides real-time data display, customizable data logging, historical graph display of logged data, and an easy to use interface with integrated help menus. MSView also features several setup and configuration wizards for the Prostar-MPPT, TriStar, TriStar-MPPT, TriStar-MPPT 600V, SunSaver MPPT, SunSaver Duo, and Relay Driver.
NOTE: The latest firmware updates for all applicable products are also included in this MSView download.SunSaver-MPPTs MUST be updated to firmware version v09 or later to enable lighting control functionality.

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MSView is a PC software utility that allows a PC to connect to supported Morningstar products. It provides real-time data display, customizable data logging, historical graph display of logged data, and an easy to use interface with integrated help menus. MSView also features several setup and configuration wizards for the Prostar-MPPT, TriStar, TriStar-MPPT, TriStar-MPPT 600V, SunSaver MPPT, SunSaver Duo, and Relay Driver.
NOTE: The latest firmware updates for all applicable products are also included in this MSView download.SunSaver-MPPTs MUST be updated to firmware version v09 or later to enable lighting control functionality.

Version: 1.6.34.0

• – Includes support for EMC-1 & PSPWM Gen3.
• – Minor scaling fixes for other controllers

Version: 1.6.44.0

• – PSPWM / PSPPT Summary Screen Swap
• – Connection Sharing between Real-Time Data & Setup Wizards

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This is the latest firmware update for f the TriStar MPPT 600V charge controller.
To update the TriStar MPPT 600V firmware, download this file and the MSLoad PC software utility found in the Related Items section on this page. This firmware update contains all fixes to date. Only the latest firmware update needs to be programmed into the TriStar MPPT 600V.

v19

*****NOTE:  IF YOU HAVE CUSTOM PROGRAMMED YOUR CHARGE SETTINGS ON A PREVIOUS FIRMWARE VERSION, THE CUSTOM PROGRAMMING WILL NEED TO BE RE-PROGRAMMED INTO THE CONTROLLER AFTER THE FIRMWARE UPDATE TO v.19*****

*****NOTE:  PREVIOUS LOGGED DATA WILL NOT BE AVAILABLE AFTER THIS FIRMWARE UPDATE, IF YOU NEED TO RETAIN THE OLD LOGGED DAT PLEASE EXPORT IT BEFORE UPDATING THE FIRMWARE*****

• – ib_ref_charge_slave support added
• – regulation improvements
• – DHCP reliability fix
• – various webpage bugfixes

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Tristar-MPPT-600V CB Certificate for IEC62109-1_2010TUV Compliance

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The 2014/2015 Morningstar Product Catalog in English

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Short video highlighting Morningstar Corporation’s history and products.

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Whitepaper on Morningstar’s s high-level of innovation, R&D and engineering excellence.

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Morningstar Introduces Two New Product Innovations at Intersolar Europe 2013 – The TriStar MPPT” 600V charge controller and the Ground Fault Protection Device

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Morningstar Product Warranty

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The part numbers listed within are in compliance with Directive 2011/65/EC on the restriction of the use of certain
hazardous substances in electrical and electronic equipment (RoHS directives). This document also certifies that
the product declaration that has been provided by Morningstar Corporation is accurate.

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Documentation certifying that the TriStar-MPPT 600V controller conforms to the European testing requirements outlined by:

• EN 61000-6-1:2007 EMC Immunity, Industrial Environments
• EN 61000-6-3:2007 +A1:2011 EMC Emissions
• EN 60335-1:2010 Safety, household & similar elec. appliances
• EN 60335-2-29:2002 A1:2004+A2:2009 Safety, battery chargers
• EN/IEC 62109-1:2010 Safety of Power Converters in PV Systems
• ICES-003 Issue 5, Aug 2012 (Class B)
• UL1741 (Jan. 28, 2010)
• CSA C22.2 No. 107.1-01 (R2011)
• IEC 62109-1:2010 (JAS-ANZ Certification)
• REACH EC 1907/2006 compliant
• Electromagnetic Compatibility Directive 2004/108/EC
• Low Voltage Directive 2004/108/EC
• FCC (Title 47 of CFR), Part 15 Subpart B Class B digital device

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PDF file of the packed Weights and Dims of Morningstar products.