TRISTAR MPPT

TM

Solar Charging System Controller

Installation, Operation and Maintenance Manual

Solar Battery Charger
With

TrakStarTM

Maximum Power Point Tracking Technology

www.morningstarcorp.com

MODELSMAXIMUM POWER POINT TRACKING

TS-MPPT-30
TS-MPPT-45
TS-MPPT-60
TS-MPPT-60M

Dimensions in Inches [Millimeters]

TABLE OF CONTENTS
1.0 Important Safety Instructions
2.0 Getting Started
2.1 Overview
2.2 Versions and Ratings
2.3 Features
2.4 Regulatory Information
2.5 Optional Accessories

3.0 Installation

4
10
10
10
11
13
14

16

3.1 General Information

16

3.2 Controller Installation

18

4.0 Operation
4.1 TrakStarTM MPPT Technology
4.2 Battery Charging Information
4.3 Push-button
4.4 LED Indications
4.5 Protections, Faults & Alarms
4.6 Inspection and Maintenance

5.0 Networking and Communication
5.1 Introduction
5.2 Morningstar MeterBusTM
5.3 Serial RS-232
5.4 EIA-485 (formerly RS-485)
5.5 Ethernet

6.0 Troubleshooting
7.0 Warranty and Claim Procedure
8.0 Specifications
Appendix A - Wire Sizing Information
Certifications

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35
37
44
45
46
50

52
52
53
54
56
57

62
64
66
72
76

1.0Important Safety Instructions
SAVE THESE INSTRUCTIONS.
This manual contains important safety, installation and operating instructions for the
TriStar MPPT 150V solar controller. The following symbols are used throughout this manual to indicate potentially dangerous conditions or mark important safety instructions:!

WARNING:
Indicates a potentially dangerous condition. Use extreme caution
when performing this task.
CAUTION:
Indicates a critical procedure for safe and proper operation of thecontroller.
NOTE:
Indicates a procedure or function that is important for the safe andproper operation of the controller.

!

AVERTISSEMENT :Indique une condition potentiellement dangereuse. Faites preuved’une prudence extrême lors de la réalisation de cette tâche.
PRUDENCE :Indique une procédure critique pour l’utilisation sûre et correcte ducontrôleur.
REMARQUE :Indique une procédure ou fonction importante pour l’utilisation sûre etcorrecte du contrôleur.

Safety Information• Read all of the instructions and cautions in the manual before beginning installation.
• There are no user serviceable parts inside the TriStar MPPT 150V. Do not disassemble
or attempt to repair the controller.
WARNING: RISK OF ELECTRICAL SHOCK.
NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROM DCINPUT, AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN
FAULT CONDITIONS, BATTERY COULD BECOME OVER-CHARGED. TEST BETWEEN ALL TERMINALS AND GROUND BEFORE TOUCHING.
• External solar and battery disconnects are required.
• Disconnect all sources of power to the controller before installing or adjusting the
TriStar MPPT 150V.
• There are no fuses or disconnects inside the TriStar MPPT 150V. Do not attempt to repair.

4

Important Safety Instructions

Informations de Sécurité• Lisez toutes les instructions et les avertissements figurant dans le manuel avant decommencer l’installation.
• Le TriStar MPPT 150V ne contient aucune pièce réparable par l’utilisateur. Ne démontez
pas ni ne tentez de réparer le contrôleur.
AVERTISSEMENT: RISQUE DE CHOC ÉLETRIQUE.
NON ALIMENTATION OU AUX BORNES D’ACCESSOIRES SONT ISOLÉS 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 MPPT 150V.
• 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
Throughout this manual, NEC guidance has been provided in order to meet general safety
requirements and inform of best installation practices. It is the installer’s responsibility to ensure that
installation complies with all national and local safety code requirements.
WARNING:
This unit is not provided with a GFDI device. This charge controller must be
used with an external GFDI device as required by the Article 690 of the National
Electrical Code for the installation location.

• Mount the TriStar MPPT 150V indoors. Prevent exposure to the elements and do not allow
water to enter the controller.
• Install the TriStar MPPT 150V in a location that prevents casual contact. The
TriStar MPPT 150V heatsink can become very hot during operation.
• Use insulated tools when working with batteries.
• Avoid wearing jewelry during installation.
• The battery bank must be comprised of batteries of same type, make, and age.
• Do not smoke near the battery bank.
• Power connections must remain tight to avoid excessive heating from a loose connection.
• Use properly sized conductors and circuit interrupters.
• The grounding terminal is located in the wiring compartment and is identified by thesymbol below:

TriStar MPPT Operator’s Manual5Ground Symbol• This charge controller is to be connected to DC circuits only. These DC connections are identified
by the symbol below:

Direct Current Symbol

The TriStar MPPT 150V controller must be installed by a qualiﬁed technician in accordance with theelectrical regulations of the country where the product is installed. A means of disconnecting all
power supply poles must be provided. These disconnects must be incorporated in the ﬁxed wiring.
A permanent, reliable earth ground must be established with connection to the wiring compartment
ground terminal.
The grounding conductor must be secured against any accidental detachment. The knock-outs inthe 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 MPPT 150V à l’intérieur. Empêchez l’exposition aux éléments et la pénétrationd’eau dans le contrôleur.
• Installez le TriStar MPPT 150V dans un endroit qui empêche le contact occasionnel. Le dissipateurde 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’uneconnexion 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 identifiée par lesymbole ci-dessous estampillé dans le boit:

6

Important Safety Instructions• Ce contrôleur de charge ne doit être connecté qu’à des circuits en courant continu. Ces connexions CC sont identifiées par le symbole ci-dessous:

Le contrôleur TriStar MPPT 150V doit être installé par un technicien qualifié conformément auxrèglementations 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 déconnexion doit être incorporée dans le câblage fixe.
À l’aide de la borne de mise à la masse du TriStar MPPT 150V (dans le compartiment de câblage),
un moyen permanent et fiable de mise à la terre doit être fourni. La fixation de la mise à la terre doitêtre fixée contre tout desserrage accidentel.
Les ouvertures d’entrée au compartiment de câblage du TriStar MPPT 150V doivent êtreprotégées avec un conduit ou une bague.

Battery Safety
WARNING: A battery can present a risk of electrical shock or burn from large amountsof short-circuit current, fire, or explosion from vented gases. Observe proper precautions.
AVERTISSEMENT: Une batterie peut présenter a ris que de choc électrique ou de brûlure
de grandes quantités de court-circuit curlouer, incendie ou explosion de ventilé gaz.
Observer précautions appropriées.
WARNING: Risk of Explosion.
Proper disposal of batteries is required. Do not dispose of batteries in fire. Refer tolocal 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 specified 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.

TriStar MPPT Operator’s Manual

7

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 etpeut 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 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 sucha shock can be reduced if battery grounds are removed during installation and maintenance(applicable to equipment and remote battery supplies not having a grounded supply circuit).
• Carefully read the battery manufacturer’s instructions before installing / connecting to, or removing
batteries from, the TriStar MPPT.
• Be very careful not to short circuit the cables connected to the battery.
• Have someone nearby to assist in case of an accident.
• Explosive battery gases can be present during charging. Be certain there is enough ventilation torelease 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 theeye, 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.
• Entretien des batteries devrait être effectué ou supervisé, par un personnel bien informé sur lespiles 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’affirmative, supprimer la source du contact
avec le sol. Contact avec n’importe quelle partie d’une batterie mise à la terre peut entraîner unchoc électrique.
8

Important Safety Instructions• La probabilité d’un tel choc peut être réduite si des motifs de batterie sont supprimés pendantl’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.
• 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 suffisante 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 ManualThis manual provides detailed installation and usage instructions for the TriStar MPPT 150V
controller. Only qualified electricians and technicians who are familiar with solar system design
and wiring practices should install the TriStar MPPT 150V. The usage information in this manual isintended for the system owner/operator.

TriStar MPPT Operator’s Manual92.0 Getting Started

2.3 Features
The features of the TriStar MPPT 150V are shown in Figure 2-1 below. An explanation of eachfeature is provided.

2.1 Overview

1

Thank you for selecting the TriStar MPPT 150V solar charge controller with TrakStarTM MPPTTechnology. The TriStar MPPT 150V (TS-MPPT) is an advanced maximum power point tracking solar
battery charger. The controller features a smart tracking algorithm that finds and maintains operation
at the solar array peak power point, maximizing energy harvest.

2
17

The TriStar MPPT 150V battery charging process has been optimized for long battery life andimproved system performance. Self-diagnostics and electronic error protections prevent damage
when installation mistakes or system faults occur. The controller also features eight (8) adjustablesettings switches, several communication ports, and terminals for remote battery temperature andvoltage measurement.
Please take the time to read this operator’s manual and become familiar with the controller. This
will help you make full use of the many advantages the TriStar MPPT 150V can provide for your PV
system.

16

15

2.2 Versions and Ratings
There are four versions of TriStar MPPT 150V controller:
TriStar-MPPT-30• maximum 30 amps continuous battery current• 12, 24 and 48 Volt dc systems• maximum 150 Volt dc solar input voltage• RS-232 and MeterBusTM communication ports
TriStar-MPPT-45• maximum 45 amps continuous battery current• 12, 24 and 48 Volt dc systems• maximum 150 Volt dc solar input voltage• RS-232 and MeterBusTM communication ports
TriStar-MPPT-60• maximum 60 amps continuous battery current• 12, 24 and 48 Volt dc systems• maximum 150 Volt dc solar input voltage• RS-232, EIA-485, MeterBusTM, and Ethernet communication ports
TriStar-MPPT-60M• maximum 60 amps continuous battery current• 12, 24 and 48 Volt dc systems• maximum 150 Volt dc solar input voltage• RS-232, EIA-485, MeterBusTM, and Ethernet communication ports• Includes on-board meter display
10

Getting Started

14
3
13
4

12
5
11
6
10
9

7
8

Figure 2-1. TriStar MPPT 150V features

TriStar MPPT Operator’s Manual112.4 Regulatory Information

1 - Heatsink
Aluminum heatsink to dissipate controller heat

NOTE:
This section contains important information for safety andregulatory requirements.

2 - Mounting Hanger
Keyhole slot for mounting

3 - Settings Switches
Eight (8) settings switches to configure operation of the TriStar MPPT 150V

4 - Battery Positive Terminal (red)Power connection for Battery (+)

5 - Remote Temperature Sensor Terminals
Connection point for a Morningstar RTS to remotely monitor battery temperature

6 - LED Indicators
Three state of charge (SOC) LED indicators show charging status and controller faults

7 - MeterBusTM Port
RJ-11 socket for Morningstar MeterBusTM network connections

8 - Battery Voltage Sense Terminals

The TriStar MPPT 150V controller should be installed by a qualified technician according to the electrical rules of the country in which the product will be installed.
TriStar MPPT 150V controllers comply with the following EMC standards:•
Immunity: EN61000-6-2:1999•
Emissions: EN55022:1994 with A1 and A3 Class B1•
Safety: EN60335-1 and EN60335-2-29 (battery chargers)
A means shall be provided to ensure all pole disconnection from the power supply. This disconnection shall be incorporated in the fixed wiring.
Using the TriStar MPPT 150V grounding terminal (in the wiring compartment), a permanent and reliable means for grounding shall be provided. The clamping of the earthing shall be secured against
accidental loosening.

Terminals for battery voltage input provide accurate battery voltage measurement

The entry openings to the TriStar MPPT 150V wiring compartment shall be protected with conduit orwith a bushing.

9 - Ground Terminal
A chassis ground terminal for system grounding

FCC requirements:

10 - Ethernet Port
RJ-45 socket for LAN/internet connections (TS-MPPT-60 model only)

11 - Wiring Box with Conduit Knockouts

Termination points for wiring conduit and wire glands

12 - Wiring Box CoverSheet metal wiring box cover protects power connections

13 - Serial RS-232 Port
9-pin serial connector (female)

14 - EIA-485 Port
Four (4) position screw terminal for EIA-485 bus connections (TS-MPPT-60 model only)

15 - Solar Positive Terminal (yellow)
Power connection for Solar (+)

16 - Common Negative Power Terminals
Two (2) negative terminals for negative system cable termination

17 - Push-button Switch
Manually reset from an error or fault, also used to start/stop a manual equalization.

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 inaccordance 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 toradio 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.

12

Getting Started

TriStar MPPT Operator’s Manual132.5 Available Accessories
The following accessories are available for purchase separately from your authorized Morningstar
dealer:Remote Temperature Sensor (Model: RTS)

TriStar Digital Meter 2 / TriStar Remote Meter 2 (Models: TS-M-2 / TS-RM-2)

The TriStar MPPT controller does not have a built-in ambient temperature sensor, and without useof the RTS, there will be no temperature-compensated charging. Systems with batteries that requiretemperature-compensated charging should always be installed with an RTS.

The TriStar Digital Meter mounts directly on the TS-MPPT controller, replacing the wiring box cover.
The TriStar Remote Meter can be flush 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 selfdiagnostic information. Four (4) buttons make navigating the meter menus easy. For systems wheremultiple TS-MPPT controllers are networked together, one (1) meter can display full system information. The TriStar meters connect to the RJ- 11 MeterBusTM port on the TriStar-MPPT.

Meter Hub (HUB-1)
A Morningstar MeterBusTM network with multiple controllers requires a Meter Hub for electricalisolation. The HUB-1 allows communication between MeterBusTM compatible Morningstar products,
including the TriStar MPPT 150V controller. DIN rail compatible. See section 5.2 for more details.

Relay Driver (RD-1)

Ethernet Meterbus Converter (EMC-1)
This product is an Ethernet gateway that provides web monitoring, a Modbus TCP/IP server, and alocal web page server. End users can collect information about their off-grid PV system remotely bybridging MODBUS TCP/IP requests to serve LiveView pages, or connect with MSView monitoring
software. The EMC-1 supports all products that have a MeterBus port.

Ground-fault Protection Device (GFPD-150V)
The GFPD-150V detects power source ground faults and interrupts current as required by the U.S.
National Electrical Code.

The Relay DriverTM accessory enables the TriStar MPPT 150V to control external devices. Four (4)relay control ports can be configured (in various combinations) to perform the following tasks:• generator control (2-, 3-, and 4-wire configurations)• dry contacts for alarms and other signals• advanced load control• vent fan control• DIN rail compatible or surface mountFor more information on the Relay Driver, visit our website at www.morningstarcorp.com or inquirewith your local Morningstar dealer.

EIA-485 / RS-232 Communications Adapter (RSC-1)
Connect one or more TriStar MPPT 150V controllers to a PC or to other serial devices using the RSC1 EIA-485 adapter. The adapter converts an RS-232 serial interface to EIA-485 compliant signals. An
LED shows network activity and errors. DIN rail compatible.

14

Getting Started

TriStar MPPT Operator’s Manual153.0 Installation
3.1 General Information
The mounting location is important to the performance and operating life of the controller. The
environment must be dry and protected from water ingress. If required, the controller may beinstalled in a ventilated enclosure with sufficient air flow. Installation in a sealed enclosure may leadto overheating and a decreased product lifetime. The controller may be mounted in an enclosure withsealed batteries, but never with vented/flooded batteries. Battery fumes from vented batteries will
corrode and destroy the TriStar MPPT 150V circuits.
Multiple TriStars can be installed in parallel on the same battery bank to achieve higher charging
current. Additional parallel controllers can also be added in the future. Each TriStar MPPT 150V musthave its own solar array.
WARNING: Installation must conform to all requirements of the latest US National
Electrical Code and the Canadian Electrical Code.
AVERTISSEMENT: Installation doit être conforme à toutes les requirments US
National Electrical Code et Code Canadien d’Electricité.

!

CAUTION: Equipment Damage or Risk of Explosion
Never install the TriStar MPPT 150V in an enclosure with vented/flooded
batteries. Battery fumes are flammable and will corrode and destroy the
TriStar MPPT 150V circuits.

!

CAUTION: Equipment Damage
When installing the TriStar MPPT 150V in an enclosure, ensure sufficientventilation. Installation in a sealed enclosure will lead to over-heating anda decreased product lifetime.

!

!

PRUDENCE : Endommagement de l’équipement ou risqued’explosion
N’installez jamais le TriStar MPPT 150V dans une enceinte avec desbatteries à évent/à électrolyte liquide. Les vapeurs des batteries sontinflammables et corroderont et détruiront les circuits du TriStar MPPT
150V.
PRUDENCE : Endommagement de l’équipement
Assurez une ventilation suffisante en cas d’installation du TriStar MPPT
150V dans une enceinte. L’installation dans une enceinte hermétiqueentraîne une surchauffe et une réduction de la durée de vie du produit.

The installation is straight-forward, but it is important each step is done correctly and safely. A
mistake can lead to dangerous voltage and current levels. Be sure to carefully follow each instructionin this section. Read all instructions first before beginning installation.

• Read through the entire installation section first before beginning installation.
• Be very careful when working with batteries. Wear eye protection. Have fresh water available towash and clean any contact with battery acid.
• Use insulated tools and avoid placing metal objects near the batteries.
• Explosive battery gases may be present during charging. Be certain there is sufficient ventilation
to release the gases.
• Do not install in locations where water can enter the controller.
• Loose power connections and/or corroded wires may result in resistive connections that melt
wire insulation, burn surrounding materials, or even cause fire. Ensure tight connections and use
cable clamps to secure cables and prevent them from swaying in mobile applications.
• Stranded wires to be connected to the terminals should be prepared first with e.g. clamped
copper heads, tinned-wire ends, etc. to avoid the possibility of one conductor free out of theconnection screw, and possible contact with the metal enclosure.
• Preset charging profiles are generally designed for lead acid batteries. Custom settings can beused for varied charging requirements (see sections 3.2 and 4.2 for details). Note that somebattery types may not be compatible.
• The TriStar MPPT 150V battery connection may be wired to one battery, or a bank of batteries.
The following instructions refer to a singular battery, but it is implied that the battery connection
can be made to either one battery or a group of batteries in a battery bank.
• The TriStar MPPT 150V uses stainless steel fasteners, an anodized aluminum heat sink, andconformal coating to protect it from harsh conditions. However, for acceptable service life, extreme temperatures and marine environments should be avoided.
• The TriStar MPPT 150V prevents reverse current leakage at night, so a blocking diode is not
required in the system.
• Solar and battery disconnects and overcurrent protection are required in the system.
These protection devices are external to the TriStar MPPT 150V controller. See Section 3.2,
Step 9 - Power Connections - for requirements.
Recommended Tools:• Wire strippers• Wire cutters• #2 & #0 Phillips screwdriver• slotted screwdrivers• Pliers• Drill• 3/32” (2.5 mm) drill bit• Level• hack saw (cutting conduit)

The installation instructions are for installation of a negative grounded system. National Electrical
Code (NEC) requirements are noted on occasion for convenience, however the installer should havea complete understanding of NEC and UL requirements for photovoltaic installations.
16

Installation

TriStar MPPT Operator’s Manual173.2 Controller Installation

Step 2 - Remove the Knock-Outs

Step 1 - Remove the wiring box cover

Knockouts are provided for routing cables through conduit or wire glands. Table 3-1 below provides
the knockout sizes and quantity on the TriStar MPPT 150V wiring box. Knockout locations and dimensions are on the inside front cover.

!
!

CAUTION: Shock Hazard
Disconnect all power sources to the controller before removing the wiring box cover. Never
remove the cover when voltage exists on any of the TriStar MPPT 150V power connections.
PRUDENCE : Risque de décharge électriqueDéconnectez 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 desconnexions d’alimentation du TriStar MPPT.

Use a #2 Phillips screw driver to remove the four (4) screws that secure the wiring box cover asshown in figure 3-1 below.

Quantity

Trade Size

Hole Dimension

8

1/2” or M20

7/8” (22.2 mm)

6

1“

1 - 23/64 “ (34.5 mm)

4

1 - 1/4 “

1 - 23/32 “ (43.7 mm)Table 3-1. Knockout sizes!

CAUTION: Shock Hazard
Always use bushings, connectors, clamp connectors, or wire glands in the knockout openings toprotect wiring from sharp edges.

!

PRUDENCE : Risque de décharge électrique
Utilisez toujours des bagues, des connecteurs, des raccordements à collets ou des fouloirs dansles ouvertures afin de protéger le câblage des bords coupants.

!

CAUTION: Shock Hazard
Never route network cables in the same conduit as the power conductors.

!

PRUDENCE : Risque de décharge électrique
N’acheminez jamais les câbles réseau dans le même conduit que les conducteursd’alimentation.

Plan the routing of each conductor that will connect to the TriStar MPPT 150V before removing any
knockouts. The 1/2” (M20) knockouts are ideal for routing network cables, which must be placed inseparate conduit.

Figure 3-1. Remove the wiring box cover.

If a TriStar Digital Meter 2 display is installed, be sure to disconnect the RJ-11 cable.

18

Installation

TriStar MPPT Operator’s Manual193. Place a mark on the mounting surface at the top of the keyhole.

Step 3 - Mount to a Vertical Surface

4. Remove the controller and drill a 3/32” (2.5 mm) hole at the drill mark.

!

CAUTION: Risk of Burns
Install the TriStar MPPT 150V in a location that prevents casual contact. The
TriStar MPPT 150V heatsink can become very hot during operation.

5. Insert a #10 screw (included) into the top pilot hole. Do not tighten the screw completely.
Leave a 1/4” (6 mm) gap between the mounting surface and screw head.
6. Carefully align the keyhole on the TriStar MPPT 150V with the screw head. Slide the
TriStar MPPT 150V down over the keyhole.
7. Check for vertical plumb with a level.

M6 Screw

8. Mark two (2) mounting hole locations in the wiring box.
9. Remove the controller and drill 3/32” (2.5 mm) holes at the drill marks.
10. Carefully align the keyhole on the TriStar MPPT 150V with the screw head. Slide the
TriStar MPPT 150V down over the keyhole.
11. The pre-drilled pilot holes should align with the mounting holes in the wiring box. Secure thecontroller with two (2) #10 mounting screws.
12. Tighten the keyhole screw.

Mounting Hanger
Figure 3-2. Attaching the mounting hanger
1. Attach the mounting hanger to the bottom of the TriStar MPPT 150V with the M6 screw provided as shown in figure 3-2.
2. Place the TriStar MPPT 150V on a vertical surface protected from direct sun, high temperatures, and water. The TriStar MPPT 150V requires at least 6” (150 mm) of clearance aboveand below and at least 1” (25 mm) on each side for proper air flow as shown in figure 3-3
below.

WARM AIR

AT LEAST
1” (25 mm)

20

AT LEAST
6” (150 mm)

AT LEAST
6” (150 mm)

Step 4 - Adjust Settings Switches
Switch 1: Reserved for Future Use
Settings switch 1 should remain in the “OFF” position.
Mode

Switch 1

Solar Charging

OFF

future use

ON

Switches 2 & 3: System Voltage
Four (4) system voltage configurations are available as shown in the table below:
System Voltage

Switch 2

Switch 3

Auto

OFF

OFF

12

OFF

ON

24

ON

OFF

48

ON

ON

The “auto” setting allows the TriStar MPPT 150V to detect the system voltage automatically on startup. The test is only performed at start up and the detected system voltage will never change during
operation.

Figure 3-3. Required mounting clearance for air flow.

Generally, it is best to choose a specific system voltage. The auto detect feature should only be usedin situations where the system voltage is unknown ahead of time or in systems where the system voltage may change periodically.

Installation

TriStar MPPT Operator’s Manual

COOL AIR21

Switches 4, 5, & 6: Battery Charging Settings
It is important to select the battery type that matches the system battery to ensure proper charging
and long battery life. Refer to the specifications provided by the battery manufacturer and choose asetting that best fits the recommended charging profile.
Settings
Switches
4-5-6

1

BatteryType

Absorp.
Stage(Volts)

Float
Stage
(Volts)

14.00

13.70

EqualizeStage(Volts)EqualizeInterval(Days)

off-off-off

1 - Geloff-off-on

2 - Sealed1

14.15

13.70

14.40

28

off-on-off

3 - Sealed

14.30

13.70

14.60

28

off-on-on

4 - AGM/Flooded

14.40

13.70

15.10

28

on-off-off

5 - Flooded

14.60

13.50

15.30

28

on-off-on

6 - Flooded

14.70

13.50

15.40

28

on-on-off

7 - Flooded

15.40

13.40

16.00

14

on-on-on

8 - Custom

CustomCustomCustomCustom1

In both settings (auto and manual), the push-button can be used to start and stop battery equalization. If the selected battery charging setting does not have an equalization stage an equalization will
never occur, even if requested manually.

Switch 7

manualOFF

automatic

ON

Switch 8: Ethernet Security
The Ethernet Security switch enables or disables configuration of the TriStar MPPT 150V settings through the Ethernet connection. When switch eight is set to disabled, write commands to the
TriStar MPPT 150V custom memory are not allowed. This a safety feature to prevent unintended
changes to custom settings, but it is not a replacement for proper network security.

“Sealed” battery type includes gel and AGM batteries

All settings are for 12 Volt nominal systems. Multiply the charge voltage settings by 2 for 24 Volt systems or by 4 for 48 Volt systems. A description of each setting is provided below. See section 4.3 for
full details on battery charging and a description of each of the settings in the battery charging table.

Configuration via TCP/IP

Switch 8

disabledOFFenabledON

NOTE:
Adjustment of network settings and custom set-points is always enabled via the
RS-232 and EIA-485 connections. The Ethernet Security switch only enables/
disables remote configuration via TCP/IP.

Battery Type - The most common battery type associated with the specified charging settings.
Absorption Stage - This stage limits input current so that the Absorption voltage is maintained. As thebattery becomes more charged, the charging current continues to taper down until the battery is fully
charged.

Equalize!

Float Stage - When the battery is fully charged, the charging voltage will be reduced to the Float voltage setting.

CAUTION: Risk of Tampering
The Ethernet Security settings switch does not block write commands to devices
bridged via EIA-485.

Equalize Stage - During an equalization cycle, the charging voltage will be held constant at the specified voltage setting.

REMARQUE :Le réglage des paramètres de réseau et des points de consignes personnalisés
est toujours activé par les connexions RS-232 et EIA-485. Le contacteur desécurité Ethernet n’active/désactive que la configuration à distance par TCP/IP.

Equalize Interval - The number of days between equalization charges when the controller is configured for automatic equalizations (settings switch 7).

PRUDENCE : Risque de tentative d’altération
Le contacteur des paramètres de sécurité Ethernet ne bloque pas lescommandes d’écriture sur les dispositifs reliés par EIA-485.

!

Switch 7: Battery Equalization
Choose between manual and automatic battery equalization charging. In the manual equalization
setting, an equalization will only occur when manually started with the push-button or when requested
from the equalize menu on the TriStar meter. Automatic equalization will occur according to the battery program specified by settings switches 4, 5, & 6 in the previous step.

22

Installation

TriStar MPPT Operator’s Manual23

Step 5 - Remote Temperature Sensor
The included Remote Temperature Sensor (RTS) should always be installed if temperaturecompensated charging is required. Connect the RTS to the 2-position terminal located between thebattery (+) terminal lug and the LED stack (see figure 2-1). The RTS is supplied with 33 ft (10 m) of
22 AWG (0.34 mm2) cable. There is no polarity, so either wire (+ or -) can be connected to either
screw terminal. The RTS cable may be pulled through conduit along with the power wires. Tighten theconnector screws to 5 in-lb (0.56 Nm) of torque. Separate installation instructions are provided inside
the RTS bag.

!

!

CAUTION: Equipment Damage
The TriStar MPPT controller does not have a built-in ambient temperature sensor, andwithout use of the RTS, there will be no temperature-compensated charging. Systems withbatteries that require temperature-compensated charging should always be installed with theincluded RTS.
CAUTION: Equipment Damage
Never place the temperature sensor inside a battery cell. Both the RTS and the battery will
be damaged.
NOTE:
The RTS cable may be shortened if the full length is not needed. If a length of cable isremoved, be sure to re-install the ferrite choke on the RTS cable as close as possible to thecontroller. This choke ensures compliance with electromagnetic emissions standards.
.

!

!

PRUDENCE : Endommagement de l’équipement
Le contrôleur TriStar MPPT n’a pas de capteur de température ambiante intégré, et sansl’utilisation du RTS, il n’y aura pas de charge compensée en température. Les systèmesavec des batteries qui nécessitent une charge compensée en température doivent toujours
être installés avec le RTS inclus.
PRUDENCE : Endommagement de l’équipement
Ne placez jamais la sonde de température dans un élément de batterie. Le RTS et labatterie seraient endommagés.
REMARQUE :Le câble RTS peut être raccourci si toute la longueur n’est pas nécessaire. Si une longueurde câble est retirée, assurez-vous de réinstaller la self de ferrite sur le câble RTS aussi
près que possible du contrôleur. Ce starter assure le respect des normes d’émissionsélectromagnétiques.

Step 6 - Grounding and Ground Fault Interruption
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.
NOTE:
Conductors identified by the colors green or green/yellow should only be used
for earthing conductors.
AVERTISSEMENT :L’appareil n’est pas fourni avec un dispositif GFDI. Ce contrôleur decharge doit être utilisé avec un dispositif GFDI externe tel que requis parl’Article 690 du Code électrique national de la région de l’installation.
Use a copper wire to connect the grounding terminal in the wiring box to earth ground. The grounding
terminal is identified by the ground symbol shown below that is stamped into the wiring box just below
the terminal:

Figure 3-4. Ground Symbol

Do not connect the system negative conductor to this terminal. NEC requires the use of an
external ground fault protection device (GFPD). The TriStar MPPT 150V does not have internal ground
fault protection. The system electrical negative should be bonded through a GFPD to earth groundat one (and only one) location. The grounding point may be located in the solar circuit or the battery
circuit.
Per NEC 690.45 (A) and NEC Table 250.122, minimum sizes for copper grounding wire are:• TS-MPPT-30
10 AWG (5 mm2)
• TS-MPPT-45
10 AWG (5 mm2)
• TS-MPPT-60/M 8 AWG (8 mm2)
OR, of the same, or greater, cross-sectional area as the PV wires.
WARNING: Risk of Fire
DO NOT bond system electrical negative to earth ground at the controller.
Per NEC requirements, system negative must be bonded to earth groundthrough a GFPD at only one point.
AVERTISSEMENT : Risque d’incendie
NE LIEZ PAS le côté négatif du système à la mise à la terre au niveau ducontrôleur. Selon les exigences du CNE, le côté négatif du système doitêtre mis à la terre par un GFPD à un seul point.

24

Installation

TriStar MPPT Operator’s Manual25Step 7 - Battery Voltage Sense
The voltage at the battery connection on the TriStar MPPT 150V may differ slightly from the voltage
directly at the battery bank terminals due to connection and cable resistance. The Battery Voltage
Sense connection enables the TriStar MPPT 150V to measure the battery terminal voltage precisely
with small gauge wires that carry very little current, and thus have no voltage drop. Both battery
voltage sense wires are connected to the TriStar at the 2-position terminal located between the pushbutton and the positive (+) terminal lug (see figure 2-1).

AVERTISSEMENT : Risque de décharge électrique
N’utilisez qu’un câble de communication 300 V homologué UL.
Connect the appropriate network cables to the TriStar MPPT 150V at this time. Access to the network
ports is easier before the power cables are attached. The ports are located inside the conduit wiringbox on the lower circuit board as shown in figure 3-5.

A battery voltage sense connection is not required to operate your TriStar MPPT 150V controller, but
it is recommended for best performance. If a TriStar meter will be added to the controller, the battery
voltage sense will ensure that the voltage and diagnostic displays are very accurate.
The voltage sense wires should be cut to length as required to connect the battery to the voltage
sense terminal. The wire size can range from 16 to 24 AWG (1.0 to 0.25 mm2). A twisted pair cable isrecommended but not required. Use UL rated 300 Volt conductors. The voltage sense wires may bepulled through conduit with the power conductors.
Fuse the positive (+) voltage sense wire as close to the battery as possible. Size the fuse based on wire
ampacity - a 1A fuse can be used for #24 wire.
Tighten the connector screws to 5 in-lb (0.56 Nm) of torque.
The maximum length allowed for each battery voltage sense wire is 98 ft (30 m).
Be careful to connect the battery positive (+) terminal to the voltage sense positive (+) terminal. No
damage will occur if the polarity is reversed, but the controller cannot read a reversed sense voltage.
Connecting the voltage sense wires to the RTS terminal will cause an alarm.
If a TriStar meter is installed, check the “TriStar Settings” to confirm the Voltage Sense and the RTS(if installed) are both present and detected by the controller. MSViewTM PC software can also be used
to confirm the voltage sense is working correctly.

Step 8 - Network Connections

RS-485(4 position)

MeterBus(RJ-11)
RS-232(DB-9)

Ethernet(RJ-45)Figure 3-5. TriStar MPPT 150V network port locations

EIA-485 Connection
The four (4) position EIA-485 connector on the TriStar MPPT 150V must be removed to access theterminal screws. Remove the socket connector by firmly grasping the connector body and pullingaway from the circuit board as shown in Figure 3-6.

Network connections allow the TriStar MPPT 150V to communicate with other controller 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 theconnection(s) required for your system.
WARNING: Shock Hazard
Never route network cables in the same conduit as the power conductors.
WARNING: Shock Hazard
Only use 300 Volt UL rated communication cable.
AVERTISSEMENT : Risque de décharge électrique
N’acheminez jamais les câbles réseau dans le même conduit que lesconducteurs d’alimentation.
26

Installation

TriStar MPPT Operator’s Manual27

Step 9 - Power Connections!

CAUTION: Wiring Requirements
U.S. installed wiring must conform to all current U.S. NEC, ANSI/NFPA 70
requirements, and to any local regulations. Non-U.S. installations must meet all
national and local requirements of the country of installation.
WARNING: Fire Hazard
If multiple units are used in parallel for more charging current, the battery
conductor wiring must be sized for the total sum of all current ratings of the
combined controllers.

Figure 3-6. Removing the RS-485 socket connector

RS-232 Connection
The serial RS-232 port is a standard 9-pin (DB9) female connector. A low-profile serial connector isrecommended to save room in the wiring box.
NOTE:
The RS-232 and EIA-485 ports share hardware. Both ports cannot be usedsimultaneously.

!

AVERTISSEMENT : Risque d’incendie
Si plusieurs unités sont utilisées en parallèle pour plus de courant de charge, le câblage duconducteur de la batterie doit être dimensionné pour la somme totale de tous les courants nominauxdes contrôleurs combinés.

!

REMARQUE :Les ports RS-232 et EIA-485 partagent le matériel. Ils ne peuvent pas être utilisés
simultanément.
Ethernet Connection
The RJ-45 Ethernet jack features two (2) indicator LEDs for connection status and network traffic.
Use CAT-5 or CAT-5e twisted pair cable and RJ-45 plugs. If possible, pull the network cable throughconduit before crimping on the RJ-45 connectors. If using pre-assembled cables, take care not todamage the plugs when the cables are pulled through conduit.
MeterBusTM Connection
MeterBusTM networks use standard 4-wire or 6-wire RJ-11 telephone cables. If possible, pull the telephone cable through conduit before crimping on the RJ-11 connectors. If using pre-assembled cables,
take care not to damage the plugs when the cables are pulled through conduit.
Y-cable Connections for EMC-1 Use
TS-MPPT-30 and TS-MPPT-45 units can be Ethernet connected using the EMC-1 accessory and an
EMC-1 provided Y-cable. These models need to be connected to the EMC-1 with the Y-cable (DB-9
serial and RJ-11 plugs at the TS-MPPT) and an RJ-11 plug at the EMC-1.

28

Installation

CAUTION: Risk of Fire and ShockConnect battery terminals prior to the connection of array terminals. The battery
positive (+) terminal has a red cover, the solar positive (+) terminal has a yellow
cover.

!

PRUDENCE : Exigences de câblage
Le câblage installé aux États-Unis doit être conforme à toutes les exigences
actuelles du NEC américain, ANSI/NFPA 70 et à toute réglementation locale.
Non américain les installations doivent répondre à toutes les exigences
nationales et locales du pays d’installation.
PRUDENCE : Risque d’incendie et de décharge électrique
Branchez les bornes de la batterie avant la connexion des bornes de réseau.
La borne positive (+) de la batterie a un capuchon rouge, la borne positive (+)
solaire a un capuchon jaune.

WIRE SIZINGThe four large power terminals are sized for 14 - 2 AWG (2.5 - 33.6 mm2) wire. The terminals are
rated for copper and aluminum conductors. Use UL-listed Class B or Class C stranded wire rated
for 300 Volt and 75C or higher. Copper is recommended due to the ease of use, good conductivity,
strength and lower thermal expansion properties.
It is critical that the ampacity (or current carrying capacity) of conductors is sufficient to handle themaximum current of the power circuits. Good system design generally requires large conductor wires
that limit voltage drop losses to 2% or less.
See the APPENDIX A - Wire Sizing - for copper wire sizing instructions including minimum wire sizing
and voltage drop distance tables.

TriStar MPPT Operator’s Manual29

REQUIRED OVERCURRENT PROTECTION DEVICES (OCPD) AND DISCONNECT
SWITCHESBATTERY DISCONNECT AND OVER-CURRENT PROTECTION DEVICE SIZINGWARNING: Risk of Fire
Solar and battery overcurrent protection (breakers or fuses) are required in the system. These
protection devices are external to the TriStar MPPT controller, and must be sized as required by the
NEC or local code requirements.

The battery breaker or fused disconnect switch(es) should be located near the battery or the battery
busbar. Where the controller battery terminals are more than 1.5m (5 feet) from the battery, or wherecircuits from these terminals pass through a wall or partition, U.S. NEC requires that a means of
disconnection be provided at the battery and solar controller with overcurrent protection at the DC(battery) power source.

WARNING: Shock Hazard
The PV system requires a means of disconnecting the battery and PV array. Breaker switches
or disconnect switches can serve as a disconnecting means and should be located at a readily
accessible location. For best practices and safety guidance see NEC 690 “Part III - Disconnecting
Means” for disconnect requirements for PV systems in addition to other code requirements.
WARNING: Shock Hazard
Fuses, single-pole circuit breakers, or single-pole disconnect switches must only be installedon ungrounded system conductors. The NEC allows and may require the use of double-pole breakers
or double-pole disconnect switches which break both the grounded and ungrounded conductors of
the PV array.
WARNING: Risk of Fire
Over-current protection device interrupt ratings must be a minimum of 2kA, 3kA and 5kA for
12V, 24V, and 48V systems, respectively.
AVERTISSEMENT : Risque d’incendie
Une protection solaire et contre les surintensités de la batterie (disjoncteurs ou fusibles) est
requise dans le système. Ces dispositifs de protection sont externes au contrôleur TriStar MPPT etdoivent être dimensionnés conformément aux exigences du NEC ou du code local.
AVERTISSEMENT : Risque d’électrocution
Le système PV nécessite un moyen de déconnecter la batterie et le générateur PV. Les disjoncteurs ou les sectionneurs peuvent servir de moyens de déconnexion et doivent être situés à unendroit facilement accessible. Pour les meilleures pratiques et les conseils de sécurité, voir NEC 690“Partie III - Disconnecting Means” pour les exigences de déconnexion des systèmes PV en plus desautres exigences du code.
AVERTISSEMENT : Risque d’électrocution
Les fusibles, les disjoncteurs unipolaires ou les sectionneurs unipolaires ne doivent être installés que sur des conducteurs de système non mis à la terre. Le NEC autorise et peut exiger l’utilisation
de disjoncteurs bipolaires ou de sectionneurs bipolaires qui coupent à la fois les conducteurs mis à laterre et non mis à la terre du générateur photovoltaïque.
AVERTISSEMENT : Risque d’incendie
Les valeurs nominales d’interruption du dispositif de protection contre les surintensités doiventêtre au minimum de 2 kA, 3 kA et 5 kA pour les systèmes 12 V, 24 V et 48 V, respectivement.

The U.S. NEC requires the installation of DC breakers or fused disconnect switches in all battery
circuits in order to provide both a means of disconnection and overcurrent protection.

The minimum battery disconnect switch current rating is the current rating of the controller being
installed. To provide over-current protection when using a disconnect switch, a properly sized fuse or
breaker must be installed in series.
Battery breakers or fuses must be sized with a minimum of 125% of the continuous output current
rating of the solar controller. Recommended battery circuit fuse or breaker current ratings:
TS-MPPT-30: 40 Amps
TS-MPPT 45: 60 Amps
TS-MPPT-60/M: 75 or 80 AmpsPV INPUT DISCONNECT AND OVER-CURRENT PROTECTION DEVICE SIZINGWARNING: Shock and Fire Hazards
The solar array open-circuit voltage (Voc) at the worst-case (coldest) module temperature must
not exceed the PV disconnect or overcurrent protection voltage ratings.
AVERTISSEMENT : Risques d’électrocution et d’incendie
La tension en circuit ouvert du générateur solaire (Voc) à la température de module la plus
défavorable (la plus froide) doit
ne pas dépasser les valeurs nominales de tension de déconnexion PV ou de protection contre lessurintensités.
As defined in NEC Section 690.9, PV input disconnect switches must have a current rating greater than or equal to the maximum PV array current (PV array Isc multiplied 1.25). PV array Isc =number of strings multiplied by the module Isc (STC) rating. Note that individual PV string circuits do
not require disconnects.
NEC Section 690.9 also provides requirements for overcurrent protection. The PV input breakeror fuse current rating should not be less than the next higher breaker rating above 125% of the
maximum PV array current (156% of the PV array Isc). Maximum PV breaker or fuse ratings are:
TS-MPPT-30: 40 Amps
TS-MPPT 45: 60 Amps
TS-MPPT-60/M: 80 Amps
If 156% of PV array Isc is greater than the maximum PV input breaker or fuse current rating, use themaximum input breaker or fuse current rating above.

30

Installation

TriStar MPPT Operator’s Manual31String over-current protection is also required for parallel strings and are typically included with the PV
string combiner. There may be other code requirements specific to the installation of a particular PV
array.

CONNECT THE POWER WIRESWARNING: Shock Hazard
The solar PV array can produce open-circuit voltages in excess of 150 Vdc whenin sunlight. Verify that the solar input breaker or disconnect has been opened(disconnected) before installing the system wires.
AVERTISSEMENT : Risque de décharge électrique
Le réseau PV solaire peut produire des tensions de circuit ouvert supérieures à 150
Vdc à la lumière du soleil. Vérifiez que le coupe-circuit ou l’interrupteur d’entrée
solaire a été ouvert (déconnexion) avant d’installer les câbles du système.

Solar Battery -Battery +(Common Negative)
Figure 3-7. Power terminal locations

Connect the four (4) power conductors shown in Figure 3-7 above in the following steps:
1. Confirm that the system input and output disconnect switches are both turned off before
connecting the power wires to the controller. There are no disconnect switches inside the
TriStar MPPT 150V.
2. Provide for strain relief if the bottom knockouts are used and conduit is not used.
3. Pull the wires into the wiring box. The Remote Temperature Sensor and Battery Sense wires
can be inside the conduit with the power conductors. It is easier to pull the RTS and Sense
wires before the power cables.

32

AVERTISSEMENT : Risque d’endommagement
Assurez-vous que la connexion a la batterie est effectuée avec la polarité
correcte. Activez le coupe-circuit/interrupteur de la batterie et mesure la tension
sur les câbles ouverts AVANT la connexion au TriStar MPPT 150V. Déconnectez
le coupe-circuit/interrupteur de la batterie avant le câblage sur le contrôleur.
4. Connect the Battery (+) wire to the Battery (+) terminal on the TriStar MPPT 150V. The
Battery (+) terminal has a red cover.
5. Connect the Battery (-) wire to one of the Common Negative terminals on the
TriStar MPPT 150V.
WARNING: Risk of Damage
Be very certain that the solar connection is made with correct polarity. Turn on the solar
array breaker/disconnect and measure the voltage on the open wires BEFORE connecting
to the TriStar MPPT 150V. Disconnect the solar breaker/disconnect before wiring to thecontroller.

{
Solar +WARNING: Risk of Damage
Be very certain that the battery connection is made with correct polarity. Turnon the battery breaker/disconnect and measure the voltage on the open battery
wires BEFORE connecting to the TriStar MPPT 150V. Disconnect the battery
breaker/disconnect before wiring to the controller.

Installation

AVERTISSEMENT : Risque d’endommagement
Assurez-vous que la connexion solaire est effectuée avec la polarité correcte. Activez lecoupe-circuit/interrupteur de réseau solaire et mesure la tension sur les câbles ouverts
AVANT la connexion au TriStar MPPT 150V. Déconnectez le coupe-circuit/interrupteur
solaire avant le câblage sur le contrôleur.
6. Connect the TriStar MPPT 150V battery (+) wire (through a properly sized breaker) as close
as possible to the system battery (+) post: then connect the battery (-) wire to the systembattery (-) post (system battery not shown).
7. Connect the Solar (+) wire to the Solar + terminal on the TriStar MPPT 150V. The Solar (+)
terminal has a yellow cover.
8. Connect the Solar (-) wire to one of the Common Negative terminals on the
TriStar MPPT 150V.
Torque all four (4) power terminals to 50 in-lbs (5.65 Nm)
POWER-UPWARNING: Risk of Damage
Connecting the solar array to the battery terminal will permanently damage the
TriStar MPPT 150V.

TriStar MPPT Operator’s Manual33

WARNING: Risk of Damage
Connecting the solar array or battery connection with reverse polarity will
permanently damage the TriStar MPPT 150V.
AVERTISSEMENT : Risque d’endommagement
La connexion du réseau solaire sur la borne de la batterie endommagera le
TriStar MPPT 150V de façon permanente.
AVERTISSEMENT : Risque d’endommagement
La connexion du réseau solaire ou la connexion de la batterie avec une polarité
inversée endommagera le TriStar MPPT 150V de façon permanente.
• Confirm that the Solar and Battery polarities are correct.
• Turn the battery disconnect switch on first. Observe that the LEDs indicate a successful
start-up. (LEDs blink Green - Yellow - Red in one cycle)• Note that a battery must be connected to the TriStar MPPT 150V to start and operate thecontroller. The controller will not operate only from solar input.
• Turn the solar disconnect on. If the solar array is in full sunlight, the TriStar MPPT 150V
will begin charging. If an optional TriStar Meter is installed, charging current will bereported along with charging state.

TO POWER-DOWN
WARNING: Risk of Damage
ONLY disconnect the battery from the TriStar MPPT 150V AFTER the solar input has
been disconnected. Damage to the controller may result if the battery is removed
while the TriStar MPPT 150V is charging.
AVERTISSEMENT : Risque d’endommagement
Le TriStar MPPT 150V SEULEMENT déconnecter la batterie APRÈS l’entrée solaire aété déconnectée. Le contrôleur pourrait endommager si la batterie est retirée quand le
TriStar MPPT 150V est en charge.
• Per warning above: To prevent damage, power-down must be done in
the reverse order as power-up.

4.0 Operation
The TriStar MPPT 150V operation is fully automatic. After installation is completed, there are few
operator tasks to perform. However, the operator should be familiar with the operation and care of
the TriStar MPPT 150V as described in this section.

4.1 TrakStarTM MPPT Technology
The TriStar MPPT 150V utilizes Morningstar’s TrakStarTM Maximum Power Point Tracking (MPPT)
technology to extract maximum power from the solar array. The tracking algorithm is fully automaticand does not require user adjustment. TrakStarTM technology tracks the array maximum power
point as it varies with weather conditions, ensuring that maximum power is harvested from the arraythroughout the course of the day.
Current Boost
Under most conditions, TrakStarTM MPPT technology will “boost” the solar charge current. For example, a system may have 36 Amps of solar current flowing into the TS-MPPT and 44 Amps of charge
current flowing out to the battery. The TriStar MPPT 150V does not create current! Rest assured thatthe power into the TriStar MPPT 150V is the same as the power out of the TriStar MPPT 150V. Since
power is the product of voltage and current (Volts x Amps), the following is true1:(1) Power Into the TriStar MPPT 150V = Power Out of the TriStar MPPT 150V
(2) Volts In x Amps In = Volts Out x Amps Out
1

assuming 100% efficiency. Losses in wiring and conversion exist.

If the solar module’s maximum power voltage (Vmp) is greater than the battery voltage, it follows thatthe battery current must be proportionally greater than the solar input current so that input and output
power are balanced. The greater the difference between the Vmp and battery voltage, the greater thecurrent boost. Current boost can be substantial in systems where the solar array is of a higher nominal voltage than the battery as described in the next section.
High Voltage Strings and Grid-Tie Modules
Another benefit of TrakStarTM MPPT technology is the ability to charge batteries with solar arrays ofhigher nominal voltages. For example, a 12 volt battery bank may be charged with a 12, 24, 36, or
48 volt nominal off-grid solar array. Grid-tie solar modules may also be used as long as the solar array open circuit voltage (Voc) rating will not exceed the TriStar MPPT 150V 150 Volt maximum input
voltage rating at worst-case (coldest) module temperature. The solar module documentation should
provide Voc vs. temperature data.
Higher solar input voltage results in lower solar input current for a given input power. High voltage
solar input strings allow for smaller gauge solar wiring. This is especially helpful and economical forsystems with long wiring runs between the controller and the solar array.

34

Installation

TriStar MPPT Operator’s Manual35

An Advantage Over Traditional Controllers
Traditional controllers connect the solar module directly to the battery when recharging. This requires that the solar module operate in a voltage range that is usually below the module’s Vmp. In a
12 Volt system for example, the battery voltage may range from 10 - 15 Vdc, but the module’s Vmp istypically around 16 or 17 Volts. Figure 4-1 shows typical current vs. voltage and power output curves
for a nominal 12 Volt off-grid module.

12 Volt Module
Current vs. Voltage

The TriStar MPPT 150V has a 4-stage battery charging algorithm for rapid, efficient, and safe battery
charging. Figure 4-2 shows the sequence of the stages.

TrackStar
MaximumPower
Point
Traditional
Controller
Operating Range

VOLTAGECURRENT

Maximum
Power
Point

4-Stage Charging

12 Volt Module
Output Power
POWER

Typical Battery
Voltage Range

4.2 Battery Charging Information

EQUALIZE

NIGHT

10

15 17

VOLTAGE10

15 17

VOLTAGEABSORPTION

FLOAT

NIGHT

TIME

Figure 4-1. Nominal 12 Volt Solar Module I-V curve and output power graph.

The array Vmp is the voltage where the product of output current and voltage (Amps x Volts) is greatest, which falls on the “knee” of the solar module I-V curve as shown on the left in Figure 4-1.

BULK
CHARGE

Figure 4-2. TriStar MPPT 150V Charging Algorithm

Bulk Charge Stage

Because traditional controllers do not always operate at the Vmp of the solar array, energy is wasted
that could otherwise be used to charge the battery and power system loads. The greater the difference between battery voltage and the Vmp of the module, the more energy is wasted. TrakStarTM
MPPT technology will always operate at the maximum power point resulting in less wasted energy
compared to traditional controllers.

In Bulk charging stage, the battery is not at 100% state of charge and battery voltage has not yet
charged to the Absorption voltage set-point. The controller will deliver 100% of available solar power
to recharge the battery.

Conditions That Limit the Effectiveness of MPPTThe Vmp of a solar module decreases as the temperature of the module increases. In very hot weather, the Vmp may be close or even less than battery voltage. In this situation, there will be very little orno MPPT gain compared to traditional controllers. However, systems with modules of higher nominal
voltage than the battery bank will always have an array Vmp greater than battery voltage. Additionally,
the savings in wiring due to reduced solar current make MPPT worthwhile even in hot climates.

Absorption Stage
When the battery has recharged to the Absorption voltage set-point, constant-voltage regulation isused to maintain battery voltage at the Absorption set-point. This prevents heating and excessive battery gasing. The battery is allowed to come to full state of charge at the Absorption voltage set-point.
The green SOC LED will blink once per second during Absorption charging.
The battery must remain in the Absorption charging stage for a cumulative 150 - 180 minutes, depending on battery type, before transition to the Float stage will occur. However, Absorption time will
be extended by 30 minutes if the battery discharges below 12.5 Volts (25 Volts @24 V, 50 Volts @48
V) the previous night.
The Absorption set-point is temperature compensated if the RTS is connected; otherwise,
set-points are based on the reference of 25ºC.
.

36

Operation

TriStar MPPT Operator’s Manual

voltages37

Float Stage
After the battery is fully charged in the Absorption stage, the TriStar MPPT 150V reduces thebattery voltage to the Float voltage set-point. When the battery is fully recharged, there can be no
more chemical reactions and all the charging current is turned into heat and gasing. The float stage
provides a very low rate of maintenance charging while reducing the heating and gasing of a fully
charged battery. The purpose of float is to protect the battery from long-term overcharge. The green
SOC LED will blink once every two (2) seconds during Float charging.
Once in Float stage, loads can continue to draw power from the battery. In the event that the systemload(s) exceed the solar charge current, the controller will no longer be able to maintain the battery
at the Float set-point. Should the battery voltage remain below the Float set-point for a cumulative 60
minute period, the controller will exit Float stage and return to Bulk charging.
The Float set-point is temperature compensated if the RTS is connected; otherwise, voltages
set-points are based on the reference of 25ºC.

Equalization StageWARNING: Risk of Explosion
Equalizing vented batteries produces explosive gases. The battery bank must be properly
ventilated.

!

CAUTION: Equipment Damage
Equalization increases the battery voltage to levels that may damage sensitive DC loads. Verify
all system loads are rated for the temperature compensated Equalize voltage before beginningan Equalization charge.

!

CAUTION: Equipment Damage
Excessive overcharging and gasing too vigorously can damage the battery plates and cause
shedding of active material from the plates. An equalization that is too high or long can bedamaging. Review the requirements for the particular battery being used in your system.
AVERTISSEMENT : Risque d’explosion
Les batteries à évent et compensation produisent des gaz explosifs. Le groupe de batteries doitêtre correctement ventilé.

38!

PRUDENCE : Endommagement de l’équipement
La compensation augmente la tension des batteries à des niveaux pouvant endommager lescharges sensibles en CC. Vérifiez que toutes les charges du système sont conçues pour latension de compensation par température avant de commencer une charge de compensation.

!

PRUDENCE : Endommagement de l’équipement
Une surcharge excessive et un dégagement gazeux trop vigoureux peuvent endommager les
plaques de batteries et provoquer l’élimination du matériau actif des plaques. Une compensation
trop élevée ou trop longue peut provoquer des dégâts. Examinez les exigences pour la batterie
particulière utilisée dans votre système.

Operation

Certain battery types benefit from a periodic boost charge to stir the electrolyte, level the cellvoltages, and complete the chemical reactions. Equalize charging raises the battery voltage above
the standard absorption voltage so that the electrolyte gases. The green SOC LED will blink rapidly
two (2) times per second during equalization charging.
The duration of the equalize charge is determined by the selected battery type. See table 4-1 in thissection for more details. The Equalization Time is defined as time spent at the equalize set-point. If
there is insufficient charge current to reach the equalization voltage, the equalization will terminate
after an additional 60 minutes to avoid over gasing or heating the battery. If the battery requires moretime in equalization, an equalize can be requested using the TriStar Meter or push-button to continue
for one or more additional equalization cycles.
The Equalize set-point is temperature compensated if the RTS is connected; otherwise, voltages setpoints are based on the reference of 25ºC.
.
When to Equalize
The ideal frequency of equalizations depends on the battery type (lead-calcium, lead-antimony, etc.),
the depth of discharging, battery age, temperature, and other factors. One very broad guide is toequalize flooded batteries every 1 to 3 months or every 5 to 10 deep discharges. Some batteries,
such as the L-16 group, will need more frequent equalizations.
The difference between the highest cell and lowest cell in a battery can also indicate the need for an
equalization. Either the specific gravity or the cell voltage can be measured. The battery manufacturer can recommend the specific gravity or voltage values for your particular battery.

Why Equalize?
Routine equalization cycles are often vital to the performance and life of a battery - particularly in asolar system. During battery discharge, sulfuric acid is consumed and soft lead sulfate
crystals
form on the plates. If the battery remains in a partially discharged condition, the soft crystals willturn into hard crystals over time. This process, called “lead sulfation,” causes the crystals to become
harder over time and more difficult to convert back to soft active materials.
Sulfation from chronic undercharging of the battery is the leading cause of battery failures in solar
charging systems. In addition to reducing the battery capacity, sulfate build-up is the most common
cause of buckling plates and cracked grids. Deep cycle batteries are particularly susceptible to leadsulfation.
Normal charging of the battery can convert the sulfate back to the soft active material if the battery
is fully recharged. However, a solar charged battery is seldom completely recharged, so the soft leadsulfate crystals harden over a period of time. Only a long controlled overcharge, or equalization, at ahigher voltage can reverse the hardening of sulfate crystals.

TriStar MPPT Operator’s Manual39

Preparation for Equalization
First, confirm that all of the system loads are rated for the equalization voltage. Consider that at 0°C(32°F) the equalization voltage will reach 16.75 Volts for 12 Volt L-16 batteries (67.0 Volts for 48 Volt
systems) with a temperature sensor installed. Disconnect any loads at risk of damage due to the highinput voltage.

The TriStar MPPT 150V provides seven (7) standard battery charging settings that are selectable withthe settings DIP switches (see Figure 4.1 above). These standard charging settings are suitable forlead-acid batteries ranging from sealed (gel, AGM, maintenance-free) to Flooded and L-16 cells. In
addition, an 8th charging setting provides for custom set-points using MSViewTM PC software.

If Hydrocaps are used, be sure to remove them before starting an equalization. Replace the Hydrocaps with standard battery cell caps. The Hydrocaps can get very hot during an equalization. Also, if
Hydrocaps are used, the equalization should be set for manual only (DIP switch #7 is Off).
After the equalization is finished, add distilled water to each cell to replace gasing losses. Check thatthe battery plates are covered.
Equalize a Sealed Battery?
The Battery Charging Settings table (see table 4-1 in this section) shows two sealed battery settings
with an Equalization cycles. These are minimal “boost” cycles to level individual cells. This is not an
equalization, and will not vent gas from sealed batteries that require up to 14.4V charging (12V battery). Many VRLA batteries, including AGM and gel, have charging requirements up to 14.4V (12V
battery). Depending on the battery manufacturer’s recommendation, the “boost” cycle for sealed cells
can be disabled by setting the equalize setting switch to manual, if required.

Shared Settings

Value

Units

Absorption Extension Voltage

12.50

Volts

Absorption Extension Time

Absorption Time + 30

minutes

Float Exit Timeout

60

minutes

Float Cancel Voltage

12.30

Volts

Equalize Time + 60

minutes-5

millivolts / °C / cell

Equalize Timeout
Temperature Compensation Coefficient
1

1

25°C reference
Table 4-2. Battery settings that are shared between all battery types

The shared settings in Table 4-2 above are common to all battery types. The following
illustrations graphically explain the shared settings.
Absorption Extension

Battery Charging Settings

ExtendedAbsorption

Preset TriStar MPPT 150V battery charging options are shown in tables 4-1 and 4-2 below. All voltage
settings listed are for nominal 12 Volt batteries. Multiply the voltage settings by two (2) for 24 Volt batteries or by four (4) for 48 Volt systems.

Bulk

Absorption

Float

NOTE: These settings are general guidelines for use at the operator’s discretion. The
TriStar MPPT 150V can be set or programmed to charge to virtually any specificrequirements, but only the battery manufacturer can recommend optimal settings fortheir products.
Settings
Switches
4-5-6

1

BatteryType

off-off-off

1 - GelAbsorp.
Stage(Volts)

Float
Stage
(Volts)EqualizeStage(Volts)Absorp. Equalize
Time
Time
(Minutes) (Minutes)

EqualizeInterval(Days)

14.00

13.70

off-off-on

2 - Sealed

1

14.15

13.70

14.40

150

60

28

off-on-off

3 - Sealed1

14.30

13.70

14.60

150

60

28

off-on-on

4 - AGM/Flooded

14.40

13.70

15.10

180

120

28

on-off-off

5 - Flooded

14.60

13.50

15.30

180

120

28

on-off-on

6 - Flooded

14.70

13.50

15.40

180

180

28

on-on-off

7 - Flooded

15.40

13.40

16.00

180

180

14

on-on-on

8 - Custom

CustomCustomCustomCustomCustomCustom12.50 V

Absorption Extension Voltage

150“Sealed” battery type includes gel and AGM batteries

time (hrs)
1:00

2:00

3:00

4:00

5:00

6:00

Figure 4-3. Absorption extension charging profile.

If battery voltage discharges below 12.50 Volts (25.00 Volts @ 24 V, 50 Volts @ 48 V) the
previous night, Absorption charging will be extended on the next charge cycle as shown in figure 4-3
above. 30 minutes will be added to the normal Absorption duration.

Table 4-1. Battery charging settings for each selectable battery type40

Operation

TriStar MPPT Operator’s Manual41Absorption

Bulk

Float

Bulk

If the battery bank discharges below 12.30 Volts (24.60 Volts @ 24 V, 49.20 Volts @ 48 V) the previous night, Float charging stage will be cancelled for the next charge cycle. Figure 4-5 above illustrates this concept. At 0:00 hrs (dawn), battery voltage is below the Float Cancel threshold voltage.
The diagram shows where Float stage would have occurred if Float was not cancelled.

Absorption

Equalize Time-out
Float Time-out
Bulk

Float V

Float

Equalize

Equalize V
60 mins.
below Float
Voltage

Absorp. V

time (hrs)
1:00

2:00

3:00

4:00

5:00

Equalize timeout

6:00

Figure 4-4. Float exit time-out charging profile

After entering Float stage, the controller will only exit Float if the battery voltage remains below
Float voltage for 60 cumulative minutes. In figure 4-4, a system load turns on at 3:30 hrs when thecontroller is in Float stage, runs for one hour, and turns off at 4:30 hrs. The load current draw is larger
than the charge current, causing battery voltage to drop below Float voltage for 60 minutes. Afterthe load runs for 60 minutes, the time-out causes the controller to return to Bulk charging, and thenAbsorption stage once again. In this example, a load runs continuously for 60 minutes. However,
because the Float exit timer is cumulative, multiple momentary load events that pull the battery
voltage below Float voltage for a combined 60 minutes duration will also force an exit from Floatstage.
Float Cancel Voltage

2:00

3:00

4:00

5:00

6:00

Figure 4-6. Equalize timeout charging profile

The charging profile in figure 4-6 shows an Equalize Timeout event. The timeout timer begins as soon
as battery voltage exceeds the Absorption voltage setpoint. If there is insufficient charging current or
system loads are too large, the battery voltage may not reach the Equalize setpoint. Equalize Timeout
is a safety feature that prevents high battery voltage for extended periods of time which may damage
the battery.

Temperature Compensation

Absorption

Bulktime (hrs)
1:00

All charging settings are based on 25°C (77°F). If the battery temperature varies by 5°C, the charging setting will change by 0.15 Volts for a 12 Volt battery. This is a substantial change in the charging of the battery, and the use of the Remote Temperature Sensor (RTS) is recommended to adjust
charging to the actual battery temperature.
The need for temperature compensation depends on the temperature variations, battery type, how
the system is used, and other factors. If the battery appears to be gasing too much or not charging
enough, the RTS can be added at any time after the system has been installed. See Section 2.3 Step 4 for installation instructions.

Float cancelled this charge cycle

12.30 V

Float Cancel Voltage

time (hrs)
1:00

2:00

3:00

4:00

5:00

Figure 4-5. Float cancelled charging profile

42

Operation

6:00

Battery Sense
Voltage drops are unavoidable in power cables that carry current, including the TriStar MPPT 150V
battery cables. If Battery Sense wires are not used, the controller must use the voltage reading at thebattery power terminals for regulation. Due to voltage drops in the battery cables, the battery power
connection voltage will be higher than the actual battery bank voltage while charging the battery.
TriStar MPPT Operator’s Manual43

Two sense wires, sized from 1.0 to 0.25 mm2 (16 to 24 AWG), can be used for battery voltage sense.
Because these wires carry no current, the voltage at the TriStar will be identical to the battery voltage.
A 2-position terminal is used for the battery sense connection. Generally accepted wiring practice is tolimit voltage drops between the charger and the battery to 2%.
Even properly sized wiring with 2% drop can result in a 0.29 Volt drop for 14.4V charging (or 1.15
Volt for a 48 Volt nominal system). Voltage drops will cause some undercharging of the battery. The
controller will begin Absorption or limit equalization at a lower battery voltage because the controllermeasures a higher voltage at the controller’s terminals than is the actual battery voltage. For
example, if the controller is programmed to start Absorption at 14.4V, when the controller “sees”
14.4V at its battery terminals, the true battery voltage would only be 14.1V if there is a 0.3V drop
between the controller and battery.
Note that the battery sense wires will not power the controller, and the sense wires will not compensate for losses in the power wires between the controller and the battery. The battery sense wires areused to improve the accuracy of the battery charging.
See Section 3.2 - Step 7 for instructions on how to connect the battery sense wires.

4.3 Push-button
The following functions can be enabled with the push-button (located on the front cover):
PUSH• Reset from an error or fault.
• Reset the battery service indication if this has been activated in custom settings. A newservice period will be started, and the flashing LEDs will stop blinking. If the battery service is performed before the LEDs begin blinking, the push-button must be pushed at thetime when the LEDs are blinking to reset the service interval and stop the blinking.
PUSH AND HOLD 5 SECONDS• Request battery equalization manually. The TriStar MPPT 150V will begin equalization in either the manual or automatic equalization mode. Equalization will begin when
there is sufficient solar power to charge the battery up to the equalization voltage. The
LEDs will blink the sequence defined in table 4-3 below to confirm that an equalize has
been requested. The equalization request will automatically stop per the battery typeselected (see Section 4.4). Equalization will only occur if the selected battery type has anequalization stage.
• Stop an equalization that is in progress. This will be effective in either the manual or
automatic mode. The equalization will be terminated. The LEDs will blink to confirm theequalize has been cancelled as shown in table 4-3 below.
Push-button Action

SOC LED Indication1

Manual Equalization Started

Green / Yellow / Red - Green / Yellow / Red - Green - Green

Stop Equalization

Green / Yellow / Red - Green / Yellow / Red - Red - Red

NOTE:
For multiple TriStar MPPT 150V controllers on a MeterBusTM network, initialize a battery
equalization using the TriStar meter so that all controllers are synchronized.
REMARQUE :Avec plusieurs contrôleurs TriStar MPPT 150V sur un réseau MeterBusTM, initialisez une
compensation de batteries à l’aide de l’outil de mesure TriStar afin de synchroniser tous lescontrôleurs.

Note that if two or more TriStar MPPT 150V controllers are charging in parallel, each controller
may attempt to equalize on a different day. Systems with multiple controllers should only equalize
manually to ensure synchronization between controllers.

4.4 LED Indications
Valuable information can be provided by the three LEDs visible through the front cover. Although
there are many different LED indications, they have similar patterns to make it easier to interpret each
LED display. Consider as three groups of indications: General Transitions // Battery Status // Faults &Alarms.
LED Display Explanation
G = green LED is lit
Y - R = yellow LED is lit, then red LED is lit alone
G / Y = green and yellow are both lit at the same time
G / Y - R = green & yellow both lit, then red is lit alone
Sequencing LED patterns (faults) repeat until the fault is cleared

General Transitions• Controller start-up• Equalize start request• Equalize cancelled• Battery service is required1
1

G - Y - R (one cycle)
G / Y/ R - G / Y / R - G - G
G/Y/R-G/Y/R-R-R
all three LEDs blinking until service is reset

Battery service notification is only enabled in custom settings, or when any custom edit is programmed

Battery Status• General state-of-charge• Absorption state• Equalization state• Float state

See battery SOC LED indications below
G blinking (½ second on / ½ second off)
G fast blink (2.5 times per second)
G slow blink (1 second on / 1 second off)

Table 4-3. Manual equalization LED indications

44

Operation

TriStar MPPT Operator’s Manual45Faults & Alarms• Over-temperature• High voltage disconnect• DIP switch fault• Self-test faults• Remote Temperature Sensor (RTS)• Battery voltage sense• Battery over-current

Y - R sequencing
G - R sequencing
R -Y - G sequencing
R - Y - G sequencing
G - R sequencing, with constant yellow
G - R sequencing, with constant yellow
R / Y - G sequencing

Battery State-of-Charge LED Indications
G
G/Y
Y
Y/R
R

80% to 95% SOC
60% to 80% SOC
35% to 60% SOC
0% to 35% SOC
battery is discharging

Alarms are events or conditions that may require the TriStar MPPT 150V to modify operation. Alarms
are commonly used to alert the user that the controller is nearing a specific voltage, current, or
temperature limit. Alarm conditions are only displayed on the TriStar Meter.

Protections
Solar Overload
The TriStar MPPT 150V will limit battery current to the Maximum Battery Current rating. An over-sized
solar array will not operate at peak power while the controller is limiting battery current. The TriStar
MPPT 150V Recommended Maximum PV Array Input Power ratings are provided as a best practices
guideline for array oversizing. For more information, refer to the Electrical Specifications on p. 66.
Solar Short Circuit
The TriStar MPPT 150V will disconnect the solar input if a short circuit is detected in the solar wiring.
Charging automatically resumes when the short is cleared. No LED indication.

Refer to the Specifications (Section 8.0) for the State-of-Charge voltages.
Note that because these State-of-Charge LED displays are for all battery types and system designs,
they are only approximate indications of the battery charge state.

High Input Voltage Current Limit
The TriStar MPPT 150V will limit the solar input current as the solar array Voc approaches the maximum input voltge rating. The array Voc should never exceed the 150 volt maximum input voltage see the array voltage de-rating graph in Appendix.

Ethernet Jack Indications

Very Low Battery Voltage
If battery discharges below ~7 Volts the controller will go into brownout and shut down. When thebattery voltage rises above the 8 Volt minimum operating voltage, the controller will restart.

In addition to the SOC LEDs, two (2) small LEDs can be found on the Ethernet RJ-45 jack inside thewiring box. These LEDs indicate the LAN/WAN network link and activity status as follows:
Condition
Network Connection OK
Network Activity
Error

Green LED
ON
ON
OFF

Yellow LED
OFF
Blinking
ON

4.5 Protections, Faults & Alarms
The TriStar MPPT 150V protections and automatic recovery are important features that ensure thesafe operation of the system. Additionally, the TriStar MPPT 150V features real-time self diagnostics
that report Fault and Alarm conditions as they occur.
Faults are events or conditions that require the TriStar MPPT 150V to cease operation. A Fault usually occurs when a limit such as voltage, current, or temperature has been surpassed. Fault conditions
are indicated with unique LED sequences and are also displayed on the TriStar Meter.

46

Operation

FaultsRemote Temperature Sensor Failure (G - R sequencing, with constant yellow)
If a fault in the RTS (such as a short circuit, open circuit, loose terminal) occurs after the RTS has
been working, the LEDs will indicate a failure. However, if the controller is restarted with a failed RTS,
the controller may not detect that the RTS is connected, and the LEDs will not indicate a problem. A
TriStar meter or the PC software can be used to determine if an RTS is detected and working properly.
Battery Voltage Sense Failure (G - R sequencing, with constant yellow)
If a fault in the battery sense connection (such as a short circuit, open circuit or loose terminal) occurs
after the battery sense has been working, the LEDs will indicate a failure. If the controller is restarted
with the failure still present, the controller may not detect that the battery sense is connected and theLEDs will not indicate a fault. A TriStar meter or the PC software can be used to determine if the battery sense is working properly.

TriStar MPPT Operator’s Manual47Battery Over-Current (R / Y - G)
While rare, if battery charging current exceeds approximately 130% of the controller’s output current
rating, this fault can occur. The fault is generally related to fast, large battery voltage transients(connecting a very heavy or capacitive load like an inverter) that are faster than the controller canregulate and it shuts off to protect the circuitry. The controller will automatically re-start in 10
seconds.
Settings (DIP) Switch Changed (R-Y-G sequencing)
If a settings switch is changed while there is power to the controller, the LEDs will begin sequencing and the solar input will disconnect. The controller must be re-started to clear the fault and begin
operation with the new settings.
Battery High Voltage Disconnect (G-R sequencing)This fault is set when battery voltage is above normal operating limits. The controller will disconnect
the solar input and set a High Voltage Disconnect fault. This fault is commonly caused by other charging sources in the system charging the battery above the TriStar MPPT 150V regulation voltage.
When the battery voltage returns to normal levels, the fault will automatically clear.
Custom Settings Edit (R -Y- G sequencing)A value has been modified in custom settings memory. The controller will stop charging and indicate
a fault condition. After all settings have been modified, the controller must be reset by removing andthen restoring power to the controller. The new programmed settings will be used after the power
reset.

Current Limit
The array power exceeds the rating of the controller. This alarm indicates that the TriStar MPPT 150V
is limiting battery current to the maximum current rating.
RTS Open
The Remote Temperature Sensor is not connected to the controller. Use of the RTS is recommended
for proper battery charging.
Heatsink Temperature Sensor Open / Shorted
The heatsink temperature sensor is damaged. Return the controller to an authorized Morningstar
dealer for service.
Battery Sense Out of Range / Disconnected
A battery sense wire is disconnected. Inspect the battery sense connections. This alarm is set whenthe voltage at the battery sense voltage differs by more than 5 volts from the voltage at the battery
terminals.
Uncalibrated
The controller was not factory calibrated. Return the controller to an authorized Morningstar dealer forservice.

Firmware Update Failure
The firmware update was not successfully programmed. The controller will not indicate the full power-up LED sequence of G - Y - R when power to the controller is reset. Instead, the controller will
display green and then stop on yellow. The yellow LED will continue to be lit and the controller will
not complete start up or begin charging. Retry the firmware update. The firmware must be successfully loaded before the controller will start up.

AlarmsHigh Temperature Current Limit
The TriStar MPPT 150V will limit the solar input current if the heatsink temperature exceeds safe
limits. Solar charge current will be tapered back (to 0 amps if needed) to reduce the heatsink temperature. The TriStar MPPT 150V is designed to operate at full rated current at the maximum ambient
temperature. This alarm indicates that there is insufficient airflow and that the heatsink temperature
is approaching unsafe limits. If the controller frequently reports this alarm condition, corrective action
must be taken to provide better air flow or to relocate the controller to a cooler spot.
High Input Voltage Current Limit
The TriStar MPPT 150V will limit the solar input current as the solar array Voc approaches the maximum input voltage rating. The array Voc should never exceed the 150 Volt maximum input voltage.
See the array voltage derating graph in Section 8.0.

48

Operation

TriStar MPPT Operator’s Manual494.6 Inspection and Maintenance
WARNING: RISK OF ELECTRICAL SHOCK.
NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROMDC INPUT, AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN FAULT CONDITIONS, BATTERY COULD BECOME OVER-CHARGED. TEST BETWEENALL TERMINALS AND GROUND BEFORE TOUCHING.
AVERTISSEMENT: RISQUE DE CHOC ÉLETRIQUE.
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.

Schedule

Maintenance Items

2 weeks after installation

Re-tighten power terminal connections to speciﬁed torquevalues.

3 months after installation

Re-tighten power terminal connections to speciﬁed torquevalues.

Monthly or After Each
Equalization

For wet cell (flooded type) batteries, make sure the water levelis correct. Wet cell water levels should be checked monthly or
according to the manufacturer’s
recommendations.

WARNING: Shock Hazard
Disconnect all power sources to the controller before removing the wiring box
cover. Never remove the cover when voltage exists on the TriStar MPPT 150V power
connections.

Clean the heatsink ﬁns with a clean, dry rag.

AVERTISSEMENT : Risque de décharge électrique
Un moyen de déconnexion de tous les poteaux d'alimentation doit être fourni.
Ceux-ci se déconnecte doit être intégrée dans le câblage fixe. Ouvrir que toutes les sourced'énergie se déconnecte avant de retirer le couvercle de la contrôleur, ou accès au câblage.
Table 4-6 below lists the recommended maintenance schedule to keep your TriStar MPPT 150V
performing optimally.

Inspect the battery bank. Look for cracked or
bulging cases, and corroded terminals.

Inspect all wiring for damage or fraying.
Inspect for nesting insects.

Annually

Re-tighten all wiring terminal connections to speciﬁed torquevalues.
Inspect the system earth grounding for all components. Verify all
grounding conductors are appropriately secured to earth ground.

Table 4-4. Maintenance Schedule

50

Operation

TriStar MPPT Operator’s Manual51

5.2 Morningstar MeterBusTM

5.0Networking and Communication

Morningstar’s proprietary MeterBusTM protocol allows communication between compatible
Morningstar products. Use a MeterBusTM network to:

5.1 Introduction
The TriStar MPPT 150V provides several communication options. The TriStar MPPT 150V uses a
proprietary protocol for the MeterBusTM network and the non-proprietary open standard MODBUSTM
and MODBUS TCP/IPTM protocols for RS-232, EIA-485, and ethernet networks. Additionally, HTTP,
SMTP, and SNMP are supported for web page, email, and network message support.
Morningstar’s MSViewTM PC software provides system monitoring and logging capabilities via RS232, EIA-485, and Ethernet. MSViewTM PC software is available for free on our website at:
http://www.morningstarcorp.com
Further, hardware and third party software that supports the MODBUSTM protocol can also be used tocommunicate with a TriStar MPPT 150V.
Multiple communication ports can be used simultaneously. For example, a TriStar MPPT 150V may
be connected to a MeterBusTM network for on-site system metering, connected to the internet for
remote monitoring, and connected to an EIA-485 network to bridge data from other controllers in thesystem to an internet connection. Note that the RS-232 and EIA-485 connections share hardware andtherefore cannot be used simultaneously.

• display net system data for multiple TriStar / TriStar MPPT 150V systems**• communicate with a TriStar Digital Meter 2 or TriStar Remote Meter 2• communicate with a Relay Driver or other compatible Morningstar accessories (see section 2.5 for more details)**A Morningstar MeterBus Hub (HUB-1) and either a TriStar Digital Meter 2 (TS-M-2) or TriStar Remote Meter 2 (TS-RM-2) are required, not included.

A MeterBus Hub (model: HUB-1) is required for MeterBus networks containing multiple
TriStar MPPT 150V controllers. The ports on the hub are electrically isolated to prevent damage inthe event of broken grounds or voltage differences between controllers. Figure 5-1 below shows anexample MeterBusTM network with two (2) TriStar MPPT 150V controllers and a TriStar Remote Meter
2 (TS-RM2).
TriStar-MPPT
Controllers

Table 5-1 below provides a summary of morningstarcorp.com/supported features for each communication interface.

SNMP Alerts
Table 5-1. Communication summary

52

Networking and Communication● ● ● ● ●Text Message Alerts● ● ●Email notification

Ethernet

View data in a web browser●

Program custom settings● ● ●Update TriStar MPPT 150V firmware●

View logged data stored in the TriStar MPPT 150V internal memory● ● ● ●

View and log data with MSViewTM PC Software

EIA-485

Connect multiple TSMPPT together in a network● ● ●Connect a TSMPPT to a Relay Driver or other MS Accessory

RS-232

MeterBus

Display system/network data on a TriStar meter

MeterBusTM
Network Hub

TriStarRemote Meter

Figure 5-1. An example MeterBus network.

Up to five (5) controllers can be networked together with a single hub. Multiple hubs can be daisychained together to allow networks of up to 14 controllers and a meter.
Refer to the HUB-1 and TriStar Meter manuals for more information about Morningstar MeterBusTM
networking.

TriStar MPPT Operator’s Manual535.3 Serial RS-232
The serial port connection on the TriStar MPPT 150V is a standard 9-pin isolated RS-232 port. See
figure 3-5 for the port location.The TriStar MPPT 150V communicates through the serial port via theopen standard MODBUSTM protocol.
Connect the TriStar MPPT 150V to the serial port on a PC to:• program custom charge settings with MSViewTM PC software• view real-time data with MSViewTM PC software• log real-time data with MSViewTM PC software• configure ethernet settings• update controller firmware with MSLoadTM firmware utility
NOTE:
The RS-232 and EIA-485 ports share hardware. Both ports cannot be usedsimultaneously.

Serial Port Settings
Adjust the serial port settings as follows:• 9600 BAUD
• 8 data bits
• 1 or 2 stop bits
• no parity

The serial RS-232 connection provides a direct connection between a TriStar MPPT 150V and a PC
(or other serial device). Firmware updates can only be programmed through the RS-232 connection. The serial connection is not typically used for multi-controller networking. However, networking
is possible using a USB hub and USB-Serial cables. For more information, refer to the “Morningstar
Communications Document” at:www.morningstarcorp.com/support

NOTE:
If your PC does not have a serial port, a USB to Serial cable can be purchased
at your local electronics retailer.
The serial connection is ideal for configuring custom settings or monitoring a single
TriStar MPPT 150V controller. Figure 5-2 shows a serial connection between the controller and a PC
with MSViewTM PC software.

Serial Cable

Figure 5-2. A serial connection between a PC and the TriStar MPPT 150V

54

Networking and Communication

TriStar MPPT Operator’s Manual55

5.4 EIA-485 (formerly RS-485)

5.5 Ethernet

NOTE:
The EIA-485 connection is only available on the TS-MPPT-60/M model.

NOTE:
Ethernet is only available on the TS-MPPT-60/M model.

NOTE:
The RS-232 and EIA-485 ports share hardware. Both ports cannot be used simultaneously.

EIA-485 is a networking standard for serial communication between multiple devices on a bus. The
TriStar MPPT 150V communicates over an EIA-485 network via the open standard MODBUSTM
protocol. Use EIA-485 networking to:• connect multiple TriStar MPPT 150V controllers on a network to log and view real-timedata using MSViewTM PC software• program each controller on the network with custom charge settings using MSViewTM PC
software• connect the TriStar MPPT 150V to other Morningstar controllers with the RSC-1 Serial toEIA-485 Adapter (sold separately)• bridge an Ethernet connection through a TriStar MPPT 150V to an EIA-485 network
The EIA-485 port has four (4) connections: Power, Data A, Data B, and Ground. Data A & B are
differentially driven data lines that carry the network data. Power and Ground connections provide
power to the network. The TriStar MPPT 150V does not supply power to the EIA-485 network, therefore an external power source is required. The source voltage must be between 8-16 Vdc. For 12 Volt
systems, the network can be powered directly from the system battery. Use a DC-DC converter for
24, 36, and 48 Volt systems.

!
!

CAUTION: Equipment Damage
Tapping power off of individual batteries in a series string of batteries can cause a
voltage imbalance. Damage to the batteries may result. Always use a DC-DC converterto power the EIA-485 network if the nominal system voltage is greater than 12 volts.
PRUDENCE : Endommagement de l’équipement
L’arrêt progressif de batteries individuelles dans une série de batteries peut provoquer
un déséquilibre de tension. Les batteries peuvent être endommagées. Utilisez toujours
un convertisseur CC-CC pour convertir l’alimentation au réseau EIA-485 si la tension
nominale du système est supérieure à 12 V.

For more information on EIA-485 networking, refer to the “Morningstar Communications Document”
on our website at:!

CAUTION: Risk of Tampering
The TS-MPPT does not feature built-in network security. It is the responsibility of
the user or network administrator to place the TS-MPPT behind a network firewall toprevent unauthorized access.

!

PRUDENCE : Risque de tentative d’altération
Le TS-MPPT ne comporte pas de sécurité réseau intégrée. Il incombe à l’utilisateurou à l’administrateur du réseau de placer le TS-MPPT derrière un pare-feu réseau afind’empêcher l’accès non autorisé.

The Ethernet port supports HTTP, MODBUS TCP/IPTM, SMTP, and SNMP protocols to provide a fully
web-enabled interface between the TriStar MPPT 150V and a LAN/WAN network or the internet.
Some of the many features the Ethernet connection provides include:• program custom settings with MSViewTM PC software• monitor the controller from a web browser• modify controller settings from a web browser• log and monitor the system with MSViewTM PC software anywhere on the internet• create custom web pages to show system data
• send an email or text message if a fault, alarm, or user-defined event occurs• monitor and receive messages on an SNMP network
This section provides a summary of each of the features. For detailed information about Ethernet
connectivity and networking, refer to the, “Morningstar Communications Document” at:morningstarcorp.com/support

Network Information
Connect to the TriStar MPPT 150V via an Ethernet network (LAN/WAN) or connect the controller directly to a PC using an ethernet cross-over cable. Use CAT-5 or CAT-5e twisted pair Ethernet cables
with RJ-45 connectors. A network diagram for both scenarios is shown in figure 5-3 below.

morningstarcorp.com/support

56

Networking and Communication

TriStar MPPT Operator’s Manual57Factory Default Network Settings

Ethernet Cross-over
Cable

DHCP
Live View Web Address
IP
Subnet Mask
Gateway
Primary DNS Server
MODBUS TCP/IPTM Port

enabledhttp://tsmppt + serial number **192.168.1.253 (if DHCP is not enabled)
255.255.255.0
192.168.1.1
169.254.1.1
502** The Live View web address is unique to each controller. If the TriStar MPPT 150V serial number is 09501234, then the Live View address is: http://tsmppt09501234. The Live View address is printed on the serial label on the side of the unit for reference.

Figure 5-3. Ethernet network diagrams.

The controller’s MAC Address is located on the serial label on the side of the controller.
Two (2) LEDs on the Ethernet jack indicate link and activity status.
Condition
Network Connection OK
Network Activity
Error

Green LED
ON
ON
OFF

Yellow LED
OFF
Blinking
ON

Web Pages
Connect the TriStar MPPT 150V controller to the network using an Ethernet cable. Wait 5 to 10 minutes for the controller to connect to the network. Open a web browser on any PC on the network.
Enter the Live View web address in the address bar of the web browser. The TriStar MPPT 150V
main Live View webpage will load. Links are provided to real-time data, history, and network settings
adjustment pages.
Pages served by the TriStar MPPT 150V are ideal for retrieving quick information about the charge
controller and making adjustments to network settings. However, there is no ability to customize thelayout or data displayed. Also, information from multiple controllers cannot be displayed on the same
webpage.

Custom Settings
The TriStar MPPT 150V Setup Wizard in MSViewTM provides an interface to adjust all operating
parameters. Morningstar’s MSViewTM PC software can connect to any TriStar MPPT 150V on the
Ethernet network or through a RS-232 serial connection. Refer to the help documentation included
with MSViewTM for more information.

58

Networking and Communication

TriStar MPPT Operator’s Manual59E-mail & SMS Alerts (Text Messages)
The email and SMS alerts feature sends notification to an e-mail address or mobile phone if one of
the following occurs:• TriStar MPPT 150V self-diagnostics fault condition• TriStar MPPT 150V self-diagnostics alarm condition• User-defined event (e.g. battery voltage is less than 46 Volts)

SNMP Traps - ONLY WITH TS-MPPT-60, 60M, or using optional EMC-1
accessory
NOTE: The default IP port assignment for the SNMP
Trap Receiver is 162

Up to four e-mails, SMS alerts, or SNMP Traps (see section on next page) can be configured from the
network settings web page in the MSView TriStar MPPT 150V Setup Wizard.

Asynchronous SNMP traps are configured, and behave, similarly to e-mail/SMS alerts. An SNMP
trap receiver can be specified in MSViewTM. When a specified condition is met (alarm, fault, custom
event), a trap is sent to the receiver, notifying it of the condition.

SMS alerts can be configured from MSViewTM. Proceed to enter the outgoing SMTP server address
and username/password. NOTE: Most forms of webmail (Google, Yahoo, etc) are not supported as
the outgoing SMTP server. This step will be the same as configuring an e-mail alert.

As with e-mail and SMS alerts, the Ethernet equipped controller may have traps triggered by conditions of other MODBUSTM enabled units on an EIA-485 network.

In the recipient’s e-mail address field, you will need to enter the cell phone @ the cell phone carrier’s
SMS Gateway (i.e. 8885553333@vtext.com). Essentially you will be sending an e-mail to the recipient’s cell phone provider. The provider will then translate the e-mail into SMS format and deliver it to
the recipient’s cell phone as a text message.
Contact the cell phone provider or perform an internet search (several web sites exist listing these
SMS Gateways) to determine the proper gateway address.

View Logged Data
The TriStar MPPT 150V logs up to 200 days* of daily data. The controller always logs the standard
values listed below. Using MSView, the controller can be configured to log additional optional values
each day. The maximum number of days that can be stored decreases as the number of logged
values increases.
Standard Values• Minimum Battery Voltage• Maximum Battery Voltage• Daily Events (Equalize triggered, Entered Float, Alarm/Fault occurred, Controller Reset)• Faults / Alarms - recorded only if a fault or alarm occurs that day
Optional Values• Maximum Array Voltage• Maximum Power Output• Charge Amp-hours• Charge Watt-hours• Minimum/Maximum Battery Temperature• Charge stage regulation timers for Absorption, Float, Equalize

For telecom and industrial applications that require full SNMP monitoring of deployed systems,
the TriStar MPPT 150V WILL NOT operate as an SNMP Agent supporting the commands below,
UNLESS, a Morningstar EMC-1 accessory is installed WITH the unit. Complete SNMP (v2c)
polling capabilities and implementation, available through the required EMC-1 accessory, aredescribed in Section 8.5 of the Morningstar Communications Document (Product Connectivity
Manual) and EMC-1 product manual located at:morningstarcorp.com/support
NOTE: SNMP does not support the SET message, which allows a user to alter a setting on thedevice. This precaution helps to minimize the security and operational risks associated with theunverified user access. Morningstar’s MSView PC software can be used to make changes to device
settings, if desired.
GET
Method used by the SNMP manager to request information from a SNMP Agent on a specific OID.
GET NEXT
Method used by SNMP manager to work through an ordered list of OIDs according to the standard
MIB hierarchy.
GET BULK
A sequence of GetNext requests, allowing a large segment of the MIB hierarchy to be queried by the
SNMP manager from a managed device.
RESPONSE
Used by the SNMP Agent to deliver requested information. Also acts as an acknowledgment.

* logging only standard values

60

Networking and Communication

TriStar MPPT Operator’s Manual616.0 Troubleshooting
WARNING: RISK OF ELECTRICAL SHOCK.
NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROMDC INPUT, AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDERCERTAIN FAULT CONDITIONS, BATTERY COULD BECOME OVER-CHARGED. TESTBETWEEN ALL TERMINALS AND GROUND BEFORE TOUCHING.
AVERTISSEMENT: RISQUE DE CHOC ÉLETRIQUE.
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.
WARNING: Shock Hazard
A means of disconnecting all power supply poles must be provided. These disconnects must be incorporated in the fixed wiring. Open all power source disconnects before
removing controller wiring cover, or accessing wiring.
AVERTISSEMENT: Risque de décharge électrique
Un moyen de déconnexion de tous les poteaux d'alimentation doit être fourni.
Ceux-ci se déconnecte doit être intégrée dans le câblage fixe. Ouvrir que toutes les sourced'énergie se déconnecte avant de retirer le couvercle de la contrôleur, ou accès au câblage.

Battery Charging and Performance Issues
Problem:
No LED indications, controller does not appear to be powered
Solution:With a multi-meter, check the voltage at the battery terminals on the TriStar MPPT 150V. Battery
voltage must be 8 Vdc or greater. If the voltage on the battery terminals of the controller is between 8
and 72 Vdc and no LEDs are lit, contact your authorized Morningstar dealer for service. If no voltage
is measured, check wiring connections, fuses, and breakers.
Problem:
The TriStar MPPT 150V is not charging the battery.
Solution:
Check the three (3) battery SOC LEDs. If they are flashing a sequence, see Section 4.4 Faults &Alarms of this manual to determine the issue. If a TriStar Meter 2 is connected, the diagnostics menu
will display reported faults and alarms.

Network and Communication Issues
Problem:Cannot connect to the controller via RS-232
Solution:
Check the following:• The RS-232 cable is straight-through, not a Null Modem (cross-over)• If using a serial-USB adapter, verify that the adapter software is installed and a serial COM
port has been mapped. Check the activity light on the USB adapter if it has one. If there isno activity, the wrong COM port has been chosen or there is a configuration issue with theadapter.
• The default MODBUS ID of the TriStar MPPT 150V is 1. Verify that the PC software isconfigured to communicate using the correct MODBUS ID.
Problem:Cannot connect to the controller via EIA-485
Solution:
Check the following:• The RS-232 port is not in use. The EIA-485 and RS-232 ports cannot be used simultaneously. Only one port can be used at a time.
• The RSC-1 adapter used to connect the PC to the EIA-485 network shows a green LED
and pulses red when a connection is attempted. See the RSC-1 documentation for more
information.
• Each controller or device on the EIA-485 network has been programmed with a unique
MODBUS ID.
• A serial cross-over (Null Modem) cable is used for the connection between the PC and theMorningstar RSC-1 485 Adapter. A straight-through serial cable will not work.
• Power is supplied to the 4-wire bus on the Power/Ground lines. The bus requires voltage
in the range: 8 - 16 Vdc.
• All bus connections are secure and each terminal is wired in parallel: line A to line A, line B
to line B, etc.
Problem:Cannot connect to the controller via Ethernet
Solution:
See the Morningstar Communications Document at:
morningstarcorp.com/support

If the LED indications are normal, check the fuses, breakers, and wiring connections in the solar array
wiring. With a multi-meter, check the array voltage directly at the TriStar MPPT 150V solar input terminals. Input voltage must be greater than battery voltage before charging will begin.
62

Troubleshooting

TriStar MPPT Operator’s Manual637.0 Warranty and Claim Procedure
WARRANTY EXCLUSIONS AND LIMITATIONS:WARRANTY
LIMITED WARRANTY - Morningstar Solar Charge Controllers and Inverters
SureSine Family (Gen 2) inverters and all other Morningstar Professional SeriesTM products, except
the SureSineTM-300 Classic (Gen 1) inverter, are warrantied to be free from defects in materials
and workmanship for a period of FIVE (5) years from the date of shipment to the original end user.
Warranty on replaced units, or ﬁeld-replaced components, will be limited only to the duration of theoriginal product coverage.
Morningstar Essentials SeriesTM products, and SureSineTM-300 Classic (Gen 1) inverter, are warrantied
to be free from defects in materials and workmanship for a period of TWO (2) years from the date ofshipment to the original end user. Warranty on replaced units, or ﬁeld-replaced components, will belimited only to the duration of the original product coverage.
Morningstar will, at its option, repair or replace any such defective units.
CLAIM PROCEDURE:
Before requesting warranty service, check the operator’s manual, including any troubeshooting
section, to verify product failure. To begin the warranty replacement process, contact your authorized
Morningstar distributor or dealer for assistance with troubleshooting and, if necessary, obtaining an
RMA number.
An RMA number must be issued by Morningstar prior to return of any unit(s) under thiswarranty. Required RMA information:(A) purchase location - business or company name - and date(B) full model and serial numbers (SN is 8-digits on unit bar label)(C) failure behavior, including LED indications(D) array conﬁguration, panel Pmax, Voc, Vmp, Isc, and nominal battery voltage; these
speciﬁcations are needed to receive assistance.
(E) multi-meter available (for ﬁeld troubleshooting)This warranty does not apply under the following conditions:• Damage by accident, negligence, abuse or improper use• PV or load currents exceeding the ratings of the product• Unauthorized product modiﬁcation or attempted repair• Damage occurring during shipment• Damage resulting from acts of nature such as lightning, weather extremes, or infestation

THE WARRANTY AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE AND IN LIEU OF ALL
OTHERS, EXPRESS OR IMPLIED. MORNINGSTAR SPECIFICALLY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE. No Morningstar distributor, agent or employee isauthorized to make any modiﬁcation or extension to this warranty.
MORNINGSTAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OFANY KIND, INCLUDING BUT NOT LIMITED TO LOST PROFITS, DOWNTIME, GOODWILL ORDAMAGE TO EQUIPMENT OR PROPERTY.

Morningstar Corporation
8 Pheasant Run, Newtown, PA 18940 USA(215) 321-4457
www.morningstarcorp.com
support@morningstarcorp.com

If, after the dealer is contacted, they are not able to assist with the warranty claim, contact
Morningstar Technical support at support@morningstarcorp.com. Please provide proof of purchasedate and location, and all other details listed in the preceding paragraph.

(Cont.)

R19-1/23

64

Warranty and Claim Procedure

TriStar MPPT Operator’s Manual65

8.0 Specifications
Charging Set-points:

Electrical
TS-MPPT-30
Nominal System Voltage
Maximum Battery Current

30 AmpsMaximum Solar Input Voltage
Battery Operating Voltage Range
Nominal Maximum Output Power

TS-MPPT-45

Settings
Switches

TS-MPPT-60/M

ALL: 12, 24 or 48 Volts dc

sw: 4-5-6

45 Amps

off-off-off

ALL: 150 Volts dc

Absorp.
Stage

Float
Stage

EqualizeStage

Absorp.
Time

EqualizeTime

Equalize
Timeout

EqualizeInterval

Volts

Minutes

Minutes

Minutes

Days

Volts

Volts

1

1 - Sealed

14.00

13.70

off-off-on

2 - Sealed

1

14.15

13.70

14.40

150

60

120

28

ALL: 8 - 72 Volts dc

off-on-off

3 - Sealed

1

14.30

13.70

14.60

150

60

120

28

off-on-on

4 - AGM/Flooded

14.40

13.70

15.10

180

120

180

28

on-off-off

5 - Flooded

14.60

13.50

15.30

180

120

180

28

on-off-on

6 - Flooded

14.70

13.50

15.40

180

180

240

28

on-on-off

7 - Flooded

15.40

13.40

16.00

180

180

240

14

CustomCustomCustomCustom

60 Amps1

12 Volt

400 Watts

600 Watts

800 Watts

24 Volt

800 Watts

1200 Watts

1600 Watts

48 Volt

1600 Watts

2400 Watts

3200 Watts

Recommended Maximum PV Array
Input Power

1

12 Volt

550 Watts

750 Watts

1100 Watts

24 Volt

1100 Watts

1500 Watts

2100 Watts

48 Volt

2100 Watts

3000 Watts

4200 Watts

Voltage Accuracy

BatteryType150

on-on-on 8 - Custom
CustomCustomCustom“Sealed” battery type includes gel and AGM batteries.
See section 4.2 for more information

NOTE:
All charging voltage set-points listed are for 12 Volt systems.
Multiply 2X for 24 Volt systems, 4X for 48 Volt systems.

12 / 24 V: ≤ 0.1% ± 50 mV
48 V: ≤ 0.1% ± 100 mV

Self consumption (tare loss)

ALL: 1.3 - 2.7 Watts

Transient Surge Protection

ALL: 4500 Watts / port

1

These power levels refer to the maximum wattage each of the TS-MPPTs can process at a certain battery voltage. Higher
power arrays can be used without damaging a controller, but array cost-benefits will be reduced at power levels much beyond
the nominal ratings. Array oversizing should be considered on a case-by-case basis. See the Morningstar String Calculator andrelated technical support documentation at https://www.morningstarcorp.com/arrayoversizing

Battery Charging
Charging algorithm
Charging stages
Temperature compensation coefficient
Temperature compensation range
Temperature compensated set-points

66

4 - stage
Bulk, Absorption, Float, Equalize-5 mV / °C / cell (25 °C ref.)-30 °C to +80 °C
Absorption, Float, Equalize, HVD

Specifications

TriStar MPPT Operator’s Manual67Battery Charging Status LEDs

De-ratings
Battery Charging Status
Equalize charging stage

Green Flashing - 1/2 sec on, 1/2 sec off

Absorption charging stage

Green Flashing (slow) - 1 sec on, 1 sec off

Float charging stage

Green

13.3 Volts ≤ Vbattery

Green & Yellow

13.0 Volts ≤ Vbattery < 13.3 Volts

Yellow

12.7 Volts ≤ Vbattery < 13.0 Volts

Yellow & Red

12.0 Volts ≤ Vbattery < 12.7 Volts

Red

Vbattery < 12.0 Volts

40

30

20

10

0
110

115

120

125

2.5 mm2 / #14 AWG
33.6 mm2 / #2 AWG
5.65 Nm / 50 in-lb

130

135

140

145

150

155

Array Voltage (Volts)

0.25 mm2 / 24 AWG
1.0 mm2 / 16 AWG
0.40 Nm / 3.5 in-lb
M20 & 1/2”, 1”, 1 - 1/4”
Vertical surface

Battery Current vs. Heatsink Temperature
7060

Environmental

50

Below 2000 meters-40 °C to +45 °C-55 °C to +85 °C
100% N.C.
IP20
Type 1 (indoor & vented)

Protections
Solar high voltage disconnect
Solar high voltage reconnect
Battery high voltage disconnect
Battery high voltage reconnect
High temperature disconnect
High temperature reconnect

40

Current
Battery(Amps)

Operating Altitude
Ambient Temperature Range
Storage Temperature
Humidity
Enclosure68

50

R A N G E !

(H) 291 mm / 11.44”(W) 130 mm / 5.12”(D) 142 mm / 5.58”
4.14 kg / 9 lbs 2 oz
11.6 kg / 25 lbs 9oz

Product Weight:
Shipping Weight (2 pcs/carton)
Power terminals:
Minimum wire size:
Maximum wire size:
Recommended torque:
RTS / Sense terminals:
Minimum wire size
Maximum wire size
Recommended torque
Knockouts (trade sizes):
Mounting:

70

60

Mechanical
Dimensions:

Battery Current vs. Array Voltage

O V E R - V O L T A G E

Green Flashing (fast) - 2.5 times per second

Battery Current (Amps)

LED Indication

30

20

10

0
60

65

70

75

80

85

90

95

Heatsink Temperature (degrees C)

Specifications

TriStar MPPT Operator’s Manual69Efficiency

TriStar MPPT 48 Volt Efficiency
TriStar MPPT 12 Volt Efficiency

100

98
97

13 Vmp96

16.5 Vmp

97

efficiency (%)

66 Vmp94
93

66 Vmp83 Vmp98 Vmp98

95

efficiency (%)

52 Vmp99

98 Vmp

92

96
95
94
93

91

92

90

91

89

90

88

0
0

50

100

150

200

250

300

350

400

450

500

550

600

650

700

750

output power (Watts)

200

400

600

800

1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000

output power (Watts)
Battery @ 51.2 V, 25 C ambient, firmware ver. 08 or later

Battery @ 12.8 V, 25 C ambient, firmware ver. 08 or later

TriStar MPPT 24 Volt Efficiency
99

efficiency (%)

26 Vmp98

33 Vmp97

66 Vmp96

98 Vmp

95
94
93
92
91
90
89
0

100

200

300

400

500

600

700

800

900

1000 1100 1200 1300 1400 1500

output power (Watts)

Battery @ 25.6 V, 25 C ambient, firmware ver. 08 or later

70

Specifications

TriStar MPPT Operator’s Manual71

APPENDIX A - Wire Sizing

Minimum Battery Wire Sizes - 75°C or 90°C Rated Stranded Copper

Minimum Wire Sizing
Wire sizing requirements are based on the ampacity (or current carrying capacity) of conductors. The
NEC includes Ampacity Tables which are used to determine the ampacity for a given wire size as
indicated in Section 310.15.

MODEL

Wire Size in a raceway, cable,or earth1@30ºC

30º-45ºC@30ºC

30º-45ºC

MetricWire Size3(mm2)

Wire Size in free air2

TriStar MPPT power terminals are rated for 75ºC. When wires with a 90°C temperature rating areused with terminals that have a 75°C temperature rating, wire ampacity at 75°C must be used.

TS-MPPT-30#8 AWG#8 AWG#10 AWG#10 AWG

6 - 10

Wire ampacity requirements for the battery and PV array circuits are as follows:

TS-MPPT-45#6 AWG#4 AWG > 40°C

#8 AWG#8 AWG

10 - 18

TS-MPPT-60/M#4 AWG#3 AWG > 40°C

#6 AWG#6 AWG

16 - 25

Controller battery wire ampacity must be greater than or equal to 125% of maximum continuous
current (battery current rating of the controller)
PV array wire ampacity must meet both of the following requirements:
Must be greater than or equal to 156% of PV Array Isc without correction and adjustment factors
Must be greater than or equal to 125% of PV Array Isc with correction and adjustment factors
Correction and adjustment factors may also be required to account for the following:• maximum ambient temperature• temperatures at different parts of the circuit (rooftops or engine rooms for example)• wire terminal temperature ratings• multi conductor cables• conduit fill and other factors

Per NEC 2021 [see NEC Table 310.15(b)(16)], ampacity for not more than three current-carrying
conductors in a raceway, cable, or earth (buried)2
Per NEC 2021 [see NEC Table 310.15(b)(17)], ampacity for conductors in free air
3
Estimated. See local code requirements for metric cable sizing
1

Table A-1. Minimum Battery Stranded Wire Sizes for 75°C or 90ºC Rated Copper

Celsius to Fahrenheit ConversionsºCelsiusºFahrenheit

30

86

35

95

40

104

45

113

Table A-2. Celsius to Fahrenheit Conversions

72

Specifications

TriStar MPPT Operator’s Manual73

TriStar MPPT Voltage Drop Tables
Good system design generally requires large conductor wires that limit voltage drop losses to 2% or
less. The tables below provide wire sizing for a maximum of 2% voltage drop. Longer distance wireruns may require significantly larger wire sizes to reduce the voltage drop to an acceptable level.

2% Voltage Drop Chart for 75°C or 90ºC Stranded Copper Wire (meters), 12 Volt System
Maximum 1-way Distance (meters), 12 Volt System - multiply values by (2) for 24 Volt and by (4) for
48V, System.

2% Voltage Drop Chart for 75°C or 90ºC Stranded Copper Wire (Feet), 12 Volt System
Maximum 1-way Distance (feet), 12 Volt System - multiply values by (2) for 24 Volt and by (4) for 48V,
System.
Wire
Size
(AWG)

60A

2/0

24.6

1

1/0

1

#1

1

19.5
15.5

55A
26.9
21.3
16.9

50A
29.6
23.4
18.6

45A
32.9
26.0
20.6

40A
37.0
29.3
23.2

35A
42.3
33.5
26.5

30A
49.3
39.1
31.0

25A
59.2
46.9
37.1

20A
73.9
58.6
46.4

Wire
Size
(mm2)

60A

55A

50A

45A

40A

35A

30A

25A

20A

15A

701

7.3

8.0

8.8

9.8

11.0

12.6

14.7

17.6

22.0

29.4

501

5.1

5.5

6.1

6.8

7.6

8.7

10.2

12.2

15.3

20.3

35

3.8

4.1

4.5

5.0

5.6

6.4

7.5

9.0

11.3

15.0

25

2.7

3.0

3.3

3.6

4.1

4.6

5.4

6.5

8.1

10.8

16

1.7

1.9

2.1

2.3

2.6

2.9

3.4

4.1

5.2

6.9

1.3

1.4

1.6

1.8

2.2

2.6

3.2

4.3

1.3

1.5

1.9

2.6

1.0

1.3

1.7

0.8

1.1

15A
98.6
78.1
61.9
10

#2

12.3

13.4

14.7

16.4

18.4

21.1

24.6

29.5

36.9

49.1
6

#3

9.7

10.6

11.7

13.0

14.6

16.7

19.5

23.3

29.2

38.9
4

#4

7.7

8.4

9.3

10.3

11.6

13.3

15.5

18.6

23.2

31.0
2.5

#6

4.9

5.3

5.8

6.5

7.3

8.3

9.7

11.6

14.6

19.4

#8

3.1

3.3

3.7

4.1

4.6

5.3

6.1

7.4

9.2

12.3

2.9

3.3

3.8

4.6

5.8

7.7

2.9

3.6

4.8

2.3

3.0

1

#10
#12
#14

Wires sizes larger than 33.6 mm2 must be terminated at a splicer block locatedexternally to the TriStar MPPT. Use 33.6 mm2 or smaller wire to connect to the TriStar
MPPT to a splicer block.

Table A-4. Maximum 1-way wire distance for 12 Volt systems, stranded copper, 2% voltage drop

Wires sizes larger than #2 must be terminated at a splicer block located externally to the
TriStar MPPT. Use #2 AWG or smaller wire to connect to the TriStar MPPT to a splicer block.
1

Table A-3. Maximum 1-way wire distance for 12 Volt systems, stranded copper, 2% voltage drop

74

Specifications

TriStar MPPT Operator’s Manual75

Certifications

CertifiALL
COMPONENTSREACHCOMPLIANT

Registration, Evaluation andAuthorization of Chemicals®

TUVRheinland
CERTIFIEDFOR CURRENT DETAILED CERTIFICATION LISTINGS, REFER TO:
https://www.morningstarcorp.com/support/library
Under, “Type”, choose, “Declaration of Conformity (DOC)”, to view a list of product DOCs.

TrisStar MPPTTM, MeterBusTM are trademarks of Morningstar Corporation
MODBUSTM and MODBUS TCP/IPTM are trademarks of Modbus IDA.
© 2023 Morningstar Corporation. All rights reserved.

MS-000946 v7.2
TriStar MPPT Operator’s Manual76