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Installation and Operation Manual

1. eooooese ore nai nanny 20 3 1 Operators Tasks tede aae brane cr EA 20 2 2 Pushb ttor he eter eterne ttal elidan tens 20 3 3 LED Indications iere dei a o i ep e ne 21 3 4 Protections and Fault Recovery sss 22 3 5 Inspection and Maintenance ssssssssseseeeeetnns 25 4 0 Solar Battery Charging sss 26 4 1 PWM Battery Charging sse 26 4 2 Standard Battery Charging Programs sss 27 4 3 Temperature Effects amp Battery Voltage Sense ou eee 28 44 Edqualization onse ete emen e nre ero i EE Renta 30 4 5 Float sonemesenert cemere eem vette coe eben ed node 32 5 0 Load Cohtrol noted eet IR RS 34 5 1 Load Control Settings een tete 34 5 2 UNV DD Warming EE 35 5 3 Inductive loads Motors eet erret bc e etr re baee 35 5 4 General Load Control Notes sss 36 continued i MORNINGSTAR CORPORATION Table of Contents continued 6 0 Diversion Charge Control sss 37 6 1 Diversion Charge Control eee 37 6 2 Diversion Current Ratings 37 6 3 Standard Diversion Battery Charging Programs s 37 6 4 Selecting the Diversion Load sss 39 6 5 NEG Requirements icc nitri 41 6 6 Additional Informations cece decease tr teet 42 7 0 Custom Settings with PC Software 43 ZA Connection toa Computern teet e eere id ede 43 7 2 Using the PC Software sssssssssseseeeeeeteenene 4
2. High Voltage Disconnect See Installation Step 4 for connecting the RTS to the TriStar Digital Meter Displays Two digital meters can be added to the TriStar at any time during or after installation One version is mounted on the controller TS M the other is suitable for remote locations TS RM The manual for installation and operation of the meter displays is included with the meter The display is a 2x16 LCD meter with backlighting Four pushbuttons are used to scroll through the displays and to execute manual functions There are a series of display screens that provide information such as operating information and data operating bar charts voltage and current alarms and faults diagnostics settings In addition there are various manual functions built into the meter For example the meter can be used to reset Ah data or start stop equalizations One of 5 languages can be selected for the meter 5 MORNINGSTAR CORPORATION 2 0 TriStar Installation The installation instructions describe solar battery charging Specific instructions for the load control and diversion modes are provided as notes General Information The mounting location is important to the performance and operating life of the controller The environment must be dry and protected as noted below The controller may be installed in a ventilated enclosure with sealed batteries but never in a sealed battery enclosure or with vented batter
3. RTS is recommended for effective temperature compensated charging This remote temperature probe should not be installed for dc load control The optional Morningstar RTS is connected to the 2 position terminal located between the pushbutton and the LED s See the diagram below E Mu E Figure 2 3 Step 4 RTS Connection The RTS is supplied with 10 meters 33 ft of 0 34 mm 22 AWG cable There is no polarity so either wire or can be connected to either screw terminal The RTS cable may be pulled through the conduit with the power wires Tighten the connector screws with 0 56 Nm 5 in lb of torque Refer to the installation instructions provided with the RTS NOTE Never place the temperature sensor inside a battery cell Both the RTS and the battery will be damaged Step 5 Battery Voltage Sense Connection A battery voltage sense connection is not required to operate your TriStar controller but it is recommended for best performance in all charging and load control modes The battery voltage sense wires carry almost no current so the voltage sense input avoids the large voltage drops that can occur in the battery power conductors The voltage sense connection allows the controller to measure the actual battery voltage under all conditions In addition 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 14 TRIST
4. 10 second delay between attempts to reconnect the FET switches Even if power is disconnected the TriStar will wait for the remainder of the 10 seconds when the power is restored Solar overload R Y G sequencing If the solar input exceeds 100 of the controller s current rating the controller will reduce the average current below the TriStar s rating The controller is capable of managing up to 130 of the rated solar input When 130 rated current is exceeded the solar will be disconnected and a fault will be indicated The input FET switches will remain open for 10 seconds Then the switches are closed again and charging resumes These cycles can continue without limit The current overload is reduced to the equivalent heating of the rated current input For example a 72A solar array 120 overload will PWM down to 50A which is equivalent to the heating from a normal 60A solar input 22 TRISTAR OPERATION LOAD CONTROL Load overload R Y G sequencing If the load current exceeds 10076 of the controller s rating the controller will disconnect the load The greater the overload the faster the controller will disconnect A small overload could take a few minutes to disconnect The TriStar will attempt to reconnect the load two times Each attempt is at least 10 seconds apart If the overload remains after 2 attempts the load will remain disconnected The overload must be corrected and the controller restarted
5. 4 2 ft 5 6 ft 8 3 ft 16 7 ft 6 mm 1 06 m 1 60 m 3 19 m 10 AWG 3 5 ft 5 2 ft 10 5 ft 4 mm 1 00 m 2 01 m 12 AWG 3 3 ft 6 6 ft 2 5 mm 1 26 m 14 AWG 4 1 ft Table 2 3 a Maximum 1 Way Wire Distance 12 Volts Notes The specified wire length is for a pair of conductors from the solar load or battery source to the controller 1 way distance Figures are in meters m and feet ft For 24 volt systems multiply the 1 way length in the table by 2 For 48 volt systems multiply the 1 way length in the table by 4 Minimum Overcurrent Device Ratings To comply with NEC requirements overcurrent protection must be provided externally in the system The NEC requires that each overcurrent device is never operated at more than 80 of its rating The minimum overcurrent device ratings for TriStar controllers are as follows e TriStar 45 60 amps e TriStar 60 75 amps Voltage rating 125 Vdc e UL Listed for dc circuits The NEC requires that manually operated disconnect switches or circuit breakers must be provided for connections between the TriStar and the battery If the overcurrent devices being used are not manually operated disconnects then manual disconnect switches must be added These manual switches must be rated the same as the overcurrent devices noted above Refer to the NEC for more information 16 TRISTAR INSTALLATION Minimum Wire Size The NEC requires that the wires c
6. 8th algorithm can be used for custom setpoints using the PC software 37 MORNINGSTAR CORPORATION 6 3 1 The table below summarizes the major parameters of the standard diversion battery charging algorithms Note that all the voltages are for 12V systems 24V 2X 48V 4X All values are 25 C 77 F A B C D E F G Time Max DIP PWM Until Time Equalize Equalize Switches Absorp Float Float Equalization in Equal Interval Cycle 4 5 6 Voltage Voltage hours Voltage hours days hours off off of 13 7 13 5 3 14 0 3 28 3 off off on 13 9 13 7 3 14 2 3 28 3 of on off 14 1 13 9 4 14 4 3 28 4 of on on 14 3 14 1 4 14 6 4 28 4 on off off 14 5 14 3 4 14 8 4 28 5 on of on 147 14 5 4 15 0 4 28 5 on on off 14 9 14 7 4 15 2 4 28 5 on on on Custom Custom Custom Table 6 3 Standard Diversion Charging Programs A PWM Absorption Voltage This is the PWM Absorption stage with constant voltage charging The PWM absorption voltage is the maximum battery voltage that will be held constant B Float Voltage When the battery is fully charged the charging voltage will be reduced by 0 2 volts for all diversion settings The float voltage and transition values are adjustable with the PC software C Time Until Float This is the cumulative time in PWM before the battery voltage is reduced to the float voltage If loads are present during the PWM absorption the time to transition into float will be extended D Equalizatio
7. Disconnect power before changing DIP switches Using the PC Software Download the TriStar PC software from Morningstar s website Follow the instructions on the website for installing the software on your computer Open the TriStar PC software This software will make the connection with the TriStar via the RS 232 cable The TriStar must be powered by the battery or a power supply to complete the connection If there is a conflict between the TriStar and PC comm ports the software will provide instructions to resolve the problem Changing Setpoints Follow the instructions in the PC software CAUTION There are few limits to the changes that can be made It is the responsibility of the operator to be certain all changes are appropriate Any damage resulting to the controller or the system from TriStar setpoint adjustments will not be covered under warranty If you are not certain about each of the changes you are making the software provides for returning to the factory default settings Finish Confirm that the changes made to the TriStar are as you intended It is advisable to make a record of the changes for future reference Observe the system behavior and battery charging for a few weeks to verify that the system is operating correctly and as you intended Exit the software The PC TriStar connection can either be disconnected or left in place 43 MORNINGSTAR CORPORATION 8 0 Self Testing Diagnostics The TriSt
8. LVD 11 3V LVD 12 1V LVD 11 5V LVD 12 3V LVD 11 7V Custom Figure 2 3 Step 3 DIP Switch 4 5 6 Select one of the 7 standard load control algorithms or select the custom DIP switch for special custom settings using the PC software Refer to Section 5 1 for the 7 standard LVD settings LVD reconnect settings and current compensation values DIP Switch Number 7 Must be OFF Switch 7 Off Figure 2 3 Step 3 DIP Switch 7 In the Load Control mode DIP switch 7 must be in the OFF position DIP Switch Number 8 Must be OFF Switch 8 Figure 2 3 Step 3 DIP Switch 8 In the Load Control mode DIP switch 8 must be in the OFF position A NOTE Confirm all dip switch settings before going to the next installation steps 54 APPENDIX I Appendix 2 Diversion Charge Control DIP Switch Settings The Diversion Charge Control functions that can be adjusted with the DIP switches follow ON ON DIP OFF 128238485 amp 7 Control Mode Load 1 System Voltage 2 3 Diversion Charge Algorithm 4 5 6 Select Diversion Mode 7 Battery Equalization 8 Figure 2 3 Step 3 Diversion DIP Switch Functions As shown in the diagram all the positions are in the OFF position except switch number 1 which is in the ON position T NOTE The DIP switches should be changed only when there is no power to the controller Turn off disconnect switches and remove all power to the controller before
9. Optional remote battery temperature sensor 5 year warranty see Section 10 0 1 1 Versions and Ratings There are two standard versions of TriStar controllers TriStar 45 Rated for maximum 45 amps continuous current solar load or diversion load Rated for 12 24 48 Vdc systems TriStar 60 Rated for maximum 60 amps continuous current solar load or diversion load Rated for 12 24 48 Vdc systems To comply with the National Electric Code NEC the current rating of the controller for solar charging must be equal or greater than 125 of the solar array s short circuit current output Isc Therefore the maximum allowable solar array input to the TriStar controller for compliance with the NEC is TS 45 36 amps Isc TS 60 48 amps Isc 1 2 Operating Modes There are three distinct and independent operating modes programmed into each TriStar Only one mode of operation can be selected for an individual TriStar If a system requires a charging controller and a load controller two TriStars must be used 1 MORNINGSTAR CORPORATION Solar battery charging The energy output of a solar array is used for recharging the system battery The TriStar manages the charging process to be efficient and to maximize the life of the battery Charging includes a bulk charging stage PWM absorption float and equalization Load control When set for load control the TriStar powers loads from the battery and protects the battery fro
10. TriStar operation is fully automatic After the installation is completed there are few operator tasks to perform However the operator should be familiar with the basic operation and care of the TriStar as described below Operator s Tasks Use the pushbutton as needed see 3 2 below e Check the LEDs for status and faults see 3 3 below e Support recovery from a fault as required see 3 4 below Routine inspection and maintenance see 3 5 below If a TriStar digital meter is installed please refer to the meter manual Pushbutton In the battery charging mode both solar and diversion the following functions can be enabled with the pushbutton located on the front cover PUSH Reset from an error or fault PUSH Reset the battery service indication if this has been activated with the PC software A new service period will be started and the flashing LEDS will stop blinking If the battery service is performed before the LED s begin blinking the pushbutton must be pushed at the time when the LED s are blinking to reset the service interval and stop the blinking PUSH AND HOLD 5 SECONDS Begin battery equalization manually This will begin equalization in either the manual or automatic equalization mode The equalization will automatically stop per the battery type selected see Section 4 4 PUSH AND HOLD 5 SECONDS Stop an equalization that is in progress This will be effective in either the manual or automatic mode Th
11. about each standard battery algorithm and the equalization In the Manual Equalization mode switch 7 Off equalization will occur only when manually started with the pushbutton Automatic starting of equalization is disabled The equalization will automatically stop per the battery algorithm selected In both cases auto and manual mode the pushbutton can be used to start and stop battery equalization DIP Switch Number 8 Noise Reduction Charging Switch 8 PWM Off On Off On Figure 2 3 Step 3 DIP Switch 8 The PWM battery charging algorithm is standard for all Morningstar charge controllers However in cases where the PWM regulation causes noise inter ference with loads e g some types of telecom equipment or radios the TriStar can be converted to an On Off method of solar charge regulation It should be noted that the On Off solar charge regulation is much less effective than PWM Any noise problem should be suppressed in other ways and only if no other solution is possible should the TriStar be changed to an On Off charger LOAD CONTROL DIP switch settings are in Appendix 1 13 MORNINGSTAR CORPORATIO DIVERSION CHARGE CONTROL DIP switch settings are in Appendix 2 e NOTE Confirm all dip switch settings before going to the next installation steps Step 4 Remote Temperature Sensor RTS Cm For solar battery charging and diversion load control a remote temperature sensor
12. all power sources to the controller are disconnected 8 TRISTAR INSTALLATION 260 4 10 25 189 7 7 47 mm inches Figure 2 3 Step 2 Mounting Dimensions Step 2 Mounting Locate the TriStar on a wall protected from direct sun high temperatures and water Do not install in a confined area where battery gasses can accumulate CF NOTE When mounting the TriStar make sure the air flow around the controller and heat sink is not obstructed There should be open space above and below the heat sink and at least 75 mm 3 inches clearance around the heat sink to allow free air flow for cooling Before starting the installation place the TriStar on the wall where it will be mounted and determine where the wires will enter the controller bottom side back Remove the appropriate knockouts before mounting the controller The knockouts are sized for 1 inch and 1 25 inch conduit continued 9 MORNINGSTAR CORPORATION Step 2 Mounting continued Refer to Figure 2 3 2 Use the template provided in the shipping carton for locating the mounting holes and for stripping the wires Use two of the 10 screws provided for the two keyhole slots Leave the screw heads protruding enough to lock inside the keyhole slots about 3 8 mm 0 150 inch Mount the controller and pull it down to lock the screws into the slots Use the remaining two screws to
13. battery voltage A 2 position terminal is used for the connection 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 con troller and the battery The battery sense wires are used to improve the accuracy of the battery charging See Section 2 3 Step 5 for instructions how to connect the battery sense wires Equalization Routine equalization cycles are often vital to the performance and life of a battery particularly in a solar 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 will turn 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 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 lead sulfation Normal charging of the battery can convert the sulfate back to the soft active material if the battery is fully recharged However a solar battery is seldom completely recharged so the soft lead sulfate crystals harden over a period of time Only a
14. in the TriStar Do not disassemble or attempt to repair the controller Disconnect all sources of power to the controller before installing or adjusting the TriStar Ensure that both the battery and the solar power have been disconnected before opening the access cover There are no fuses or disconnects in the TriStar Power must be removed externally Do not allow water to enter the controller Confirm that the power wires are tightened to the correct torque to avoid excessive heating from a loose connection Ensure the enclosure is properly grounded with copper conductors The grounding terminal is located in the wiring compartment and is identified by the symbol below that is stamped into the enclosure Ground Symbol Battery Safety 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 rings and jewelry when working with batteries Use insulated tools and avoid placing metal objects in the work area continued iii MORNINGSTAR CORPORATION Battery Safety continued Carefully read the battery manuals before installing and connecting the controller 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 gasses can be present during charging Be certain there is enough ventilation to release the g
15. open the FET switches and stop diverting current from the battery This condition can damage the battery If you are not confident and certain about the installation a professional installation by your dealer is recommended 6 2 Diversion Current Ratings The maximum diversion load current capability for the two TriStar versions is 45 amps TS 45 and 60 amps TS 60 The diversion loads must be sized so that the peak load current cannot exceed these maximum ratings See section 6 4 below for selecting and sizing the diversion loads The total current for all combined charging sources wind hydro solar should be equal or less than two thirds of the controller s current rating 30A TS 45 and 40A TS 60 This limit will provide a required margin for high winds and high water flow rates as well as a margin for error in the rating and selection of the diversion load This protects against an overload and a safety disconnect in the TriStar controller which would leave the battery charging unregulated CAUTION If the TriStar s rating is exceeded and the controller dis connects the diversion load Morningstar will not be responsible for any damage resulting to the system battery or other system compo nents Refer to Morningstar s Limited Warranty in Section 10 0 6 3 Standard Diversion Battery Charging Programs The TriStar provides 7 standard diversion charging algorithms programs that are selected with the DIP switches An
16. the load as a last resort These lower LVD settings will deeply discharge the battery and should not be used for systems that may go into LVD more than once a year The LVD values in the table above are current compensated Under load the battery voltage will be reduced in proportion to the current draw by the load A short term large load could cause a premature LVD without the current compensation The LVD values in the table above are adjusted lower per the following table TS 45 TS 60 12V 15 mV per amp 10 mV per amp 24V 30 mV per amp 20 mV per amp 48V 60 mV per amp 40 mV per amp As an example consider a 24V system using a TriStar 60 with a 30 amp load 34 LOAD CONTROL The LVD will be reduced by 0 02V per the table above times 30 amps This equals 0 6V A DIP switch selected LVD of 23 4V would be reduced to 22 8V in this example Note that the LEDs are linked to the LVD setting so the LEDs are also current compensated After an LVD the load reconnect voltages are 0 25 volts per battery cell higher than the LVD for example in a 12V system the LVDg would be 1 5 volts above LVD Battery voltages can rise quickly after an LVD typically from 1 0 to 1 3 volts or more 12V system The LVDg value must be high enough to avoid cycling in and out of LVD LVD Warning When the battery is discharging and the green LED changes to the next state G Y LEDs on there are four remaining transitions to LVD refer to the LE
17. to 5 65 Nm 50 in Ibs Power Up Confirm that the solar or load and battery polarities are correct Turn the battery disconnect on first Observe the LED s to confirm a successful start up LED s blink Green Yellow Red in one cycle Note that a battery must be connected to the TriStar to start and operate the controller The controller will not operate from a solar input only Turn the solar or load disconnect on Step 7 RS 232 Adjustments The TriStar must be powered from the battery to enable use of the RS 232 PC computer connection Refer to Section 7 0 for using the RS 232 and Morningstar s PC software to change setpoints or confirm the installation settings Step 8 Finish Installation Inspect for tools and loose wires that may have been left inside the enclosure Check the power conductors to make sure they are located in the lower part of the wiring compartment and will not interfere with the cover or the optional meter assembly 18 TRISTAR INSTALLATION T NOTE If the power conductors are bent upwards and touch the meter assembly TS M option pressing the cover down on the wires can damage the meter Carefully place the cover back on the controller and install the 4 cover screws Closely observe the system behavior and battery charging for 2 to 4 weeks to confirm the installation is correct and the system is operating as expected 19 MORNINGSTAR CORPORATION 3 0 TriStar Operation The
18. used 13 of these elements in parallel will be required for the diversion load 4 2 amps per element Table in 6 4 4 x 13 54 6 amps The minimum diversion load would be the source output 35A times the voltage 30V This would require a 1 050 watt heating element rated at 30 volts Or if a 2 000W heater element rated for 120 volts is used 9 heater elements will be required to draw the required minimum diversion load at 30 volts NEC Requirements To comply with NEC 690 72 B the following requirements will apply when the TriStar is being used as a diversion charge controller in a photovoltaic system Second Independent Means If the TriStar is the only means of regulating the battery charging in a diversion charging mode then a second independent means to prevent overcharging the battery must be added to the system The second means can be another TriStar or a different means of regulating the charging 41 MORNINGSTAR CORPORATION 6 5 2 150 Percent Rating The current rating of the diversion load must be at least 15096 of the TriStar source current rating Refer to Section 6 2 Diversion Current Rating The maximum allowable current ratings for both TriStar versions are summarized below Max Input Max Diversion Current Load Rating TS 45 30A 45 A TS 60 40A 60A CAUTION The NEC requirement that the diversion load must be sized at least 15096 of the controller rating does NOT mean the diversion load can exceed the m
19. 3 L3 Changing Setpolntsuu sieht deers aad Phan ea De d ede 43 7 4 FNS e tec coen ence eee erase reU t ee sees 43 8 0 Self Testing Diagnostics 44 9 0 Battery Information reference 46 9 1 Sealed Batteries 46 9 2 Flooded Batteries orte eret tpa Ire ds 47 OS VG CSS oases 48 10 0 Warranty o oo cece eceeeseeseseeseseesceeceeeseaesaenecaeeesaeeeseeeeceesaeeeteeaeneeaeees 49 11 0 Specifications ieelpa iini cosd ndiii isinai ias 50 Appendix 1 Load Control DIP Switch Settings 52 Appendix 2 Diversion Charge Control DIP Switch Settings 55 Appendix 3 LED Indications sss 59 ii TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety installation and operating instructions for the TriStar solar controller The following symbols are used throughout this manual to indicate potentially dangerous conditions or important safety instructions AN N C WARNING Indicates a potentially dangerous condition Use extreme caution when performing this task CAUTION Indicates a critical procedure for safe and proper operation of the controller NOTE Indicates a procedure or function that is important to the safe and proper operation of the controller General Safety Information Read all the instructions and cautions in the manual before starting the installation There are no user serviceable parts
20. AR INSTALLATION The two battery voltage sense wires are connected to the TriStar at the 2 position terminal located between the pushbutton and the positive 4 terminal lug See the diagram below Figure 2 3 Step 5 Battery Sense Connection The two voltage sense wires not provided with the controller should be cut to length as required to connect the battery to the voltage sense terminal The wire size can be from 1 0 to 0 25 mm 16 to 24 AWG It is recom mended to twist the wires together every few feet twisted pair but this is not required The voltage sense wires may be pulled through the conduit with the power wires Tighten the connector screws with 0 56 Nm 5 in Ib of torque The maximum length allowed for each battery voltage sense wire is 30 meters 98 ft The battery sense terminal has polarity Be careful to connect the battery positive terminal to the voltage sense positive terminal No damage will occur if the polarity is reversed but many functions of the controller can be affected If a TriStar meter is installed check the TriStar Settings to confirm the Voltage Sense and the RTS if installed are both present and seen by the controller The PC software can also be used to confirm the voltage sense is working correctly Do not connect the voltage sense wires to the RTS terminal This may cause an alarm Review the installation diagram for the correct battery voltage sense connection Not
21. D indications in Section 3 3 Each of these LED displays will serve as a warning of an approaching LVD The final warning is a blinking red LED state The amount of time from the initial G Y display until the load disconnect will depend on many factors These include The rate of discharge The health of the battery The LVD setting For a typical system with a healthy battery and an LVD setting of about 11 7 volts there could be approximately 10 hours per LED transition The LVD would occur about 40 hours from the first G Y display under constant load with no charging Another significant factor affecting the warning time is the LVD voltage setpoint Lower LVD voltage settings may result in the battery discharging 7096 or 8096 of its capacity In this case the battery s very low charge state will result in the voltage dropping much faster At the lowest LVD settings there could be as little as 2 or 3 hours of warning between LED transitions for a healthy battery The amount of time it takes to transition through the LEDs to LVD can vary greatly for different systems It may be worthwhile to measure the time it takes for your system to transition from one LED state to the next Do this under typical discharging loads This will provide a good reference for how long it will take for your system to reach LVD It can also provide a benchmark for judging the health of your battery over time Inductive Loads Motors Fo
22. ON CHARGE CONTROL 6 4 5 6 5 1 Voltage Power Current 120V 2000 W 16 7 A 60V 48V nominal 500 W 83A 30V 24V nominal 125 W 4 2 A 15V 12V nominal 31 W 2 1 A Whether using dc rated loads the first table or 120V elements the total diversion load current must not exceed the current rating of the TriStar Minimum Diversion Load The diversion load must be large enough to divert all the current produced by the source wind hydro etc This value is the maximum battery voltage times the maximum source current For example if a hydro source can generate up to 30 amps of current in a nominal 48 volt system 60V maximum the minimum diversion load size 60V x 30A 1 800 watts for loads rated at 60 volts General Sizing Example Consider a 24V system with a wind turbine that is rated to generate 35A of current A TriStar 45 will not provide the 150 diversion load margin and the TS 45 is only rated for 30A of source current The TS 45 will not provide enough margin for wind gusts and overloads so a TS 60 should be used The diversion load should be sized for 52 5A 15096 of the source current up to 60A the rating of the TriStar 60 If 55A is selected for the diversion load the load must be capable of diverting 55A at 30V maximum battery voltage If a 30V heating element is used it would be rated for 1 650 watts or from 1 575W to 1 800W per the load range noted above If a 2 000 watt 120 volt heating element is
23. Section 11 0 LOAD CONTROL Load high temperature R Y sequencing When the heatsink temperature limit is reached 90 C 194 F the TriStar will disconnect the load The load will be reconnected at the lower temperature setting 70 C 158F DIVERSION CHARGE CONTROL Diversion high temperature R Y sequencing When the heat sink temperature reaches 80 C the TriStar will change to an on off regulation mode to reduce the temperature If the temperature reaches 90 C the load will be disconnected The load is reconnected at 70 C 23 MORNINGSTAR CORPORATIO Solar high voltage disconnect HVD R G sequencing If the battery voltage continues increasing beyond normal operating limits the controller will disconnect the solar input unless the FET switches cannot open due to a failure See Section 11 0 for the disconnect and reconnect values LOAD CONTROL Load HVD R G sequencing In the Load Control mode the HVD can only be enabled using the PC software At the battery voltage value selected in the soft ware the TriStar will disconnect the load At the selected lower voltage the load will be reconnected DIVERSION CHARGE CONTROL Diversion HVD R G sequencing HVD will be the same value as used for Solar charging In the Diversion mode an HVD condition will be indicated with the LEDs but there is no disconnect Battery removal voltage spike no LED indication Disconne
24. TRISTAR Solar System Controller Installation and Operation Manual Diversion Charge Control MORNINGSTAR 1098 Washington Crossing Road Washington Crossing PA 18977 USA phone 215 321 4457 fax 215 321 4458 email info morningstarcorp com www morningstarcorp com Table of Contents Important Safety Instructions sees iii 1 0 TriStar Description sse 1 1 1 Wersions and Ratings aee e t tige ets 1 1 2 perating MOGES inrcr ir t ocn Ra ansaa 1 1 37 Adj stability ce rer e re deg 2 WA General Use scienter pt tet i tbi iris 3 1 5 Safety and Regulatory Information sss 4 1 6 Options Available ts eee arie iaeano ri trii 5 Remote Temperature Sensor eee 5 Digital Meter Displays nrbis eee rrr 5 20 Installation oen een eerie pct dee erede 6 2 1 General Information ccccccececeeeeseeeeeeeseseseeeeeseeeeeseseaeaeeceeseaeeeeeeeeees 6 2 2 Installation Overview i detis et teen ertet tete ctn 6 2 3 InstallatiOHt Steps niaar cece nested erste reete ene EE 8 1 Remove the COVE aute ect nn te rd ene eec ebe S E 8 2 Montilii retenti oem eC Hr Y TEXTES SORA 9 3 Adjust DIP Switches 2 nie nonae teer tos 10 4 Remote Temperature Sensor ipii aysan 14 5 Battery Voltage Sense 14 6 System Wiring and Power up sss 15 7e RS 232 Adjustments nente aiiai 18 8 Finish Installation ete tete bac et uet 18 0 Operation
25. The pushbutton can also be used to reconnect the load DIVERSION CHARGE CONTROL Diversion overload R Y G sequencing If the current to the diversion load exceeds the TriStar rating the controller will attempt to reduce the load If the overload is too large the TriStar will disconnect the diversion load The controller will continue attempts to reconnect the load If the overload LED s are sequencing the diversion load is too large for the controller The size of the load must be reduced Reversed polarity If the battery polarity is reversed there will be no power to the controller and no LED s will light If the solar is reversed the controller detects nighttime and there will be no LED indication and no charging If the load is reversed loads with polarity will be damaged Be very careful to connect loads to the controller with correct polarity See Section 5 4 DIP switch fault R Y G sequencing If a DIP switch is changed while there is power to the controller the LED s will begin sequencing and the FET switches will open The controller must be restarted to clear the fault Solar high temperature R Y sequencing When the heatsink temperature limit is reached the TriStar will begin reducing the solar input current to prevent more heating If the controller continues heating to a higher temperature the solar input will then be disconnec ted The solar will be reconnected at the lower temperature see
26. ad control information and Section 6 0 for diversion Recommended tools wire cutter wire stripper slotted screw drivers phillips screwdrivers e torque wrench to 50 in lb e flashlight Before starting the installation review these safety notes Do not exceed a battery voltage of 48V nominal 24 cells Do not use a battery less than 12V 6 cells Do not connect a solar input greater than a nominal 48V array for battery charging Never exceed a Voc open circuit voltage of 125V Charge only 12 24 or 48 volt lead acid batteries when using the standard battery charging programs in the TriStar Verify the nominal charging voltage is the same as the nominal battery voltage Do not install a TriStar in a sealed compartment with batteries Never open the TriStar access cover unless both the solar and battery power has been disconnected Never allow the solar array to be connected to the TriStar with the battery disconnected This can be a dangerous condition with high open circuit solar voltages present at the terminals Follow the installation steps in order 1 through 8 Step 1 Remove the Cover Remove the 4 screws in the front cover Lift the cover until the top edge clears the heat sink and set it aside If an LCD meter display is attached to the cover disconnect the RJ 11 connector at the meter for access CAUTION Do not remove the cover if power is present at any of the terminals Verify that
27. age load disconnect LVD warning indications 5 2 Load information and general cautions are provided in the remaining sections Load Control Settings The primary purpose of a low voltage load disconnect function LVD is to protect the system battery from deep discharges that could damage the battery In the Load Control mode the TriStar provides for seven standard LVD settings that are selected by the DIP switches These are described in the table below Custom LVD settings are possible using the PC software see Section 7 0 DIP 12V 24V 48V Battery 12V 24V 48V Switch LVD LVD LVD SOC LVDk LVD R LVDp off off off 11 1 22 2 44 4 8 12 6 25 2 50 4 off off on 11 3 22 6 45 2 12 12 8 256 51 2 off on off 11 5 23 0 46 0 18 13 0 26 0 52 0 off on on 11 7 23 4 46 8 23 13 2 264 52 8 on off off 11 9 23 8 47 6 35 13 4 26 8 53 6 on off on 12 1 24 2 48 4 55 13 6 27 2 544 on on off 12 3 24 6 492 75 13 8 27 6 55 2 on on on Custom Custom Custom Table 5 1 The table above describes the standard selectable LVD battery voltages for 12 24 and 48 volt systems The LVD values are the load reconnect setpoints The Battery SOC provides a general battery state of charge figure for each LVD setting The actual battery SOC can vary considerably depending on the battery condition discharge rates and other specifics of the system NOTE The lowest LVD settings are intended for applications such as telecom that only disconnect
28. ar input breaker has been opened disconnected before installing the system wires if the controller is in the solar charging mode Using the diagram on the previous page connect the four power conductors in the following steps 1 Confirm that the 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 2 Provide for strain relief if the bottom knockouts are used and conduit is not used 3 Pull the wires into the wiring compartment The temperature probe wires and battery voltage sense wires can be inside the conduit with the power conductors 4 Connect the Battery positive wire to the Battery terminal Connect the Battery negative wire to the Battery terminal oOo uo Connect the Solar wire positive to the Solar terminal or Load Diversion 7 Connect the Solar negative wire to the Solar terminal or Load Diversion The CE certification requires that the battery conductors the battery voltage sense wires and the remote temperature sensor shall not be accessible without the use of a tool and are protected in the battery compartment Do not bend the power wires up toward the access cover If a TS M meter is used now or in the future these large wires can damage the meter assembly when the access cover is attached to the controller Torque each of the four power terminals
29. ar performs a continuous self test to monitor controller and system operation Detected problems are classified as either faults or alarms Typi cally faults are problems that stop the normal operation of the controller and require immediate attention Alarms indicate an abnormal condition but will not stop the controller s operation If a problem is detected the TriStar will alert the user to an existing fault or alarm In this situation the LED indicators will flash a particular sequence Section 3 3 references these sequences with their associated faults and alarms Flashing LED sequences can indicate conditions ranging from a simple battery service reminder to an existing short circuit in the system It is recommended that the user become familiar with the LED indications and their meanings If a TriStar meter option has been added more detailed information concerning faults and alarms will be available Menus provide text displays of the specific fault as well as indicating on the standard display screens when a problem exists Consult the meter manual for further details General Troubleshooting TriStar is not powering up Confirm that all circuit breakers and switches in the system are closed Check all fuses Check for loose wiring connections and wiring continuity e Verify that the battery voltage is not below 9Vdc brownout section 3 4 Verify that the battery power connection is not reversed polarity Flashing Sequenc
30. arging PWM absorption float and equalization stages The TriStar will accurately measure time over long intervals to manage events such as automatic equalizations or battery service notification Day and night conditions are detected by the TriStar and no blocking diodes are used in the power path LED s a pushbutton and optional digital meters provide both status information and various manual operations The date of manufacture can be found on the two bar code labels One label is on the back of the TriStar and the other is in the wiring compartment The year and week of manufacture are the first four digits of the serial number For example year week serial 03 36 0087 3 MORNINGSTAR CORPORATION 1 5 Safety and Regulatory Information Cc NOTE This section contains important information for safety and regulatory requirements The TriStar controller is intended for installation by a qualified technician according to electrical rules of each country in which the product will be installed TriStar controllers comply with the following EMC standards Immunity 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 grounding terminal in the wiring compartment a perman ent and reliab
31. arrying the system current never exceed 8096 of the conductors current rating The table below provides the minimum size of copper wire allowed by NEC for the TS 45 and TS 60 versions Wire types rated for 75 C and 90 C are included Minimum wire sizes for ambient temperatures to 45 C are provided in the table below TS 45 75C Wire 90C Wire TS 60 75C Wire 90C Wire lt 45C 16mm 6AWG 10mm 8AWG lt 45C 25 mm 4 AWG 16 mm 6 AWG Table 2 3 6b Minimum Wire Size Both copper and aluminum conductors can be used with a TriStar controller If aluminum wire is used the minimum size of the aluminum conductor must be one wire size larger than the minimum wire size specified in the table above Ground Connection Use the grounding terminal in the wiring compartment to connect a copper wire to an earth ground or similar grounding point The grounding terminal is identified by the ground symbol shown below that is stamped into the enclosure Ground Symbol The minimum size of the copper grounding wire e TS 45 6 mm 10 AWG e TS 60 10 mm 8 AWG Connect the Power Wires First confirm that the DIP switch 1 is correct for the operating mode intended Battery Solar Solar Battery Load Load Diversion Diversion Figure 2 3 Step 6 Power Wire Connections 17 MORNINGSTAR CORPORATION CAUTION The solar PV array can produce open circuit voltages over 100 Vdc when in sunlight Verify that the sol
32. asses Never smoke in the battery area f battery acid comes into contact with the skin wash with soap and water If the acid contacts the eye flood with fresh water and get medical attention Be sure the battery electrolyte level is correct before starting charging Do not attempt to charge a frozen battery Recycle the battery when it is replaced iv IMPORTANT SAFETY INSTRUCTIONS 1 0 TriStar Description The TriStar is a technically advanced solar system controller There are three operating modes programmed into each TriStar This manual describes solar battery charging and specific load control or diversion charge control instructions are inserted where required This manual will help you to become familiar with the TriStar s features and capabilities Some of these follow UL Listed UL 1741 and cUL Listed CSA C22 2 No 107 1 Complies with the US National Electric Code Complies with EMC and LVD standards for CE marking Rated for 12 24 48 volt systems and 45 or 60 amps current Fully protected with automatic and manual recovery Seven standard charging or load programs selected with DIP switches Adjustability by means of an RS 232 connection with PC software Continuous self testing with fault notification LED indications and pushbutton functions e Terminals sized for 35mm 2 AWG wire Includes battery voltage sense terminals Digital meter options mounted to TriStar or remote
33. aximum current rating of the TriStar NEVER size a diversion load that can draw more than the 45 amps or 60 amps maximum rating of the TriStar controllers 6 6 Additional Information Visit Morningstar s website www morningstarcorp com for additional diversion charge control information The website provides expanded technical support for more complex diversion load systems 42 DIVERSION CHARGE CONTROL 7 0 Custom Settings with PC Software An RS 232 connection between the TriStar and an external personal com puter PC allows many setpoints and operating parameters to be easily adjusted The adjustments can be simply a small change to one setpoint or could include extensive changes for a fully customized battery charging or load control program CAUTION Only qualified service personnel should change operating parameters with the PC software There are minimal safeguards to protect from mistakes Morningstar is not responsible for any damage resulting from custom settings Consult Morningstar s website for the latest TriStar PC software and instructions Connection to a Computer An RS 232 cable with DB9 connectors 9 pins in 2 rows will be required If the computer will be used to change battery charging or load control setpoints verify that DIP switches 4 5 6 are in the custom position On On On before connecting the TriStar to a computer The custom position is required to change setpoints See Section 2 3 Step 3
34. battery types and appropriate solar charging 27 MORNINGSTAR CORPORATION B PWM Voltage This is the PWM Absorption stage with constant voltage charging The PWM voltage is the maximum battery voltage that will be held constant As the battery becomes more charged the charging current tapers down until the battery is fully charged C Float Voltage When the battery is fully charged the charging voltage will be reduced to 13 4 volts for all battery types The float voltage and transition values are adjustable with the PC software See Section 4 5 for more details D Equalization Voltage During an equalization cycle the charging voltage will be held constant at this voltage E Time in Equalization The charging at the selected equalization voltage will continue for this number of hours This may take more than one day to complete See Section 4 4 F Equalization Interval Equalizations are typically done once a month Most of the cycles are 28 days so the equalization will begin on the same day of the week Each new cycle will be reset as the equalization starts so that a 28 day period will be maintained G Maximum Equalization Cycle If the solar array output cannot reach the equalization voltage the equalization will terminate after this many hours to avoid over gassing or heating the battery If the battery requires more time in equalization the manual pushbutton can be used to continue for one or more additional equalization cy
35. be added at any time after the system has been installed See Section 2 3 Step 4 for installation instructions The TriStar will recognize the RTS when the controller is started powered up 4 3 2 Battery Voltage Sense There can be voltage drops typically up to 3 in the power cables connect ing the battery to the TriStar If battery voltage sense wires are not used the controller will read a higher voltage at the controller s terminals than the actual battery voltage while charging the battery Although limited to 3 as the generally accepted wiring standard this can result in a 0 43 voltage drop for 14 4V charging or 1 72V for a 48 volt nominal system nd continued 29 MORNINGSTAR CORPORATION 4 3 2 Battery Voltage Sense continued These voltage drops will cause some undercharging of the battery The controller will begin PWM absorption or limit equalization at a lower battery voltage because the controller measures a higher voltage at the controller s terminals than is the actual battery voltage For example if the controller is programmed to start PWM 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 Two sense wires sized from 1 0 to 0 25 mm 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
36. bsite www sandia gov pv Ea NOTE The best charging algorithm for flooded deep cycle batteries depends on the normal depth of discharge how often the battery is cycled and the plate chemistry Consult the battery manufacturer for the recommended solar charging settings for the battery being used 48 BATTERY INFORMATION 10 0 Warranty LIMITED WARRANTY The TriStar 45 and TriStar 60 controllers are warranted to be free from defects in material and workmanship for a period of FIVE 5 years from the date of shipment to the original end user Morningstar will at its option repair or replace any such defective products CLAIM PROCEDURE Before requesting warranty service check the Operator s Manual to be certain that there is a fault with the controller Return the defective product to your authorized Morningstar distributor with shipping charges prepaid Provide proof of date and place of purchase To obtain service under this warranty the returned products must include the model serial number and detailed reason for the failure the panel type array size type of batteries and system loads This information is critical to a rapid disposition of your warranty claim Morningstar will pay the return shipping charges if the repairs are covered by the warranty WARRANTY EXCLUSIONS AND LIMITATIONS This warranty does not apply under the following conditions Damage by accident negligence abuse or improper use PV or load
37. changing a DIP switch A fault will be indicated if a switch is changed with the controller powered CAUTION The TriStar is shipped with all the switches in the OFF position Each switch position must be confirmed during instal lation A wrong setting could cause damage to the battery or other system components The DIP switch settings described below are for Diversion Charge Control only The DIP switches are shipped in the OFF position With switches 2 8 in the OFF position the following functions are present Switch Function 1 Must be ON load control 2 3 Auto voltage select 4 5 6 Lowest battery charging voltage 7 Must turn ON to select Diversion 8 Manual Equalization 55 MORNINGSTAR CORPORATION gt x S Q 2 N To configure your TriStar for the diversion battery charging and control you require follow the DIP switch adjustments described below To change a switch from OFF to ON slide the switch up toward the top of the controller Make sure each switch is fully in the ON or OFF position DIP Switch Number 1 Control Mode Solar Battery Charging Control Switch 1 Charging Off Load On Figure 2 3 Step 3 DIP Switch 1 For the Diversion Charge Control mode move the DIP switch to the ON position as shown DIP Switches Number 2 3 System Voltage Voltage Switch 2 Switch 3 Auto Off Off 12 Off On 24 On Off 48 On On ON l Auto Select 24 Volts OFF 12 Volt
38. cles These 7 standard battery charging algorithms will perform well for the majority of solar systems However for systems with specific needs beyond these standard values any or all of these values can be adjusted using the PC software See Section 7 0 4 3 Temperature Effects amp Battery Voltage Sense 4 3 1 Remote Temperature Sensor RTS The RTS is used for temperature compensated battery charging As the battery gets warmer the gassing increases As the battery gets colder it becomes more resistant to charging Depending on how much the battery temperature varies it may be important to adjust the charging for temperature changes There are three battery charging parameters that are affected by temperature PWM Absorption This is the most important part of charging that is affected by temperature because the charging may go into PWM absorption almost every day If the battery temperature is colder the charging will begin to regulate too soon and the battery may not be recharged with a limited solar resource If the battery temperature rises the battery may heat and gas too much Equalization A colder battery will lose part of the benefit of the equalization A warmer battery may heat and gas too much 28 SOLAR BATTERY CHARGING Float Float is less affected by temperature changes but it may also undercharge or gas too much depending on how much the temperature changes The RTS corrects the three charging setpoints no
39. clude ability to add water to the cells deep cycle capability vigorous recharging and equalization long operating life In cycling applications flooded batteries benefit from vigorous charging and equalization cycles with significant gassing Without this gassing the heavier electrolyte will sink to the bottom of the cell and lead to stratification This is especially true with tall cells Hydrocaps can be used to limit the gassing water loss Note that a 4 mixture of hydrogen in air is explosive if ignited Make certain the battery area is well ventilated Typical equalization voltages for flooded batteries are from 15 3 volts to 16 volts However a solar system is limited to what the solar array can provide If the equalization voltage is too high the array l V curve may go over the knee and sharply reduce the charging current Lead Calcium Calcium batteries charge at lower voltages 14 2 to 14 4 typically and have strong advantages in constant voltage or float applications Water loss can be only 1 10th of antimony cells However calcium plates are not as suitable for cycling applications Lead Selenium These batteries are similar to calcium with low internal losses and very low water consumption throughout their life Selenium plates also have poor cycling life Lead Antimony Antimony cells are rugged and provide long service life with deep discharge capability However these batteries self discharg
40. cting the battery before the solar input is discon nected can cause a large solar open circuit voltage spike to enter the system The TriStar protects against these voltage spikes but it is best to disconnect the solar input before the battery Very low battery voltage LED s are all off Below 9 volts the controller will go into brownout The controller shuts down When the battery voltage rises the controller will restart In the Load Control mode the TriStar will recover in the LVD state Remote temperature sensor RTS failure R Y G Y If a fault in the RTS such as a short circuit open circuit loose terminal occurs after the RTS has been working the LED s will indicate a failure and the solar input is disconnected However if the controller is restarted with a failed RTS the controller may not detect that the RTS is connected and the LED s will not indicate a problem A TriStar meter or the PC software can be used to determine if the RTS is working properly Battery voltage sense failure R Y G Y If a fault in the battery sense connection such as a short circuit open circuit loose terminal occurs after the battery sense has been working the LED s will indicate a failure However if the controller is restarted with the failure still present in the battery sense the controller may not detect that the battery sense is connected and the LED s will not indicate a problem A TriStar meter or the PC software can be used to d
41. cular battery being used in your system Standard Equalization Programs Both automatic and manual equalizations can be performed using either the standard charging programs see 4 2 or a custom program see 7 0 Manual Equalization The TriStar is shipped with the DIP switch set for manual equalization only This is to avoid an unexpected or unwanted automatic equalization In the manual mode the pushbutton is used to both start or stop a manual equalization Hold the pushbutton down for 5 seconds to start or stop an equalization depending on whether an equalization is in progress or not The LED s will confirm the transition all 3 LED s blink 2 times When the battery charging enters into equalization the Green LED will start fast blinking 2 3 times per second There are no limits to how many times the pushbutton can be used to start and stop equalizations Equalizations will be terminated automatically per the charging program selected if the pushbutton is not used to manually stop the equalization Automatic Equalization If the equalization DIP switch is moved to the ON position see 2 3 Step 3 the equalizations will begin automatically per the charging program selected Other than starting the automatic and manual equalizations are the same and follow the standard charging program selected The pushbutton can be used to start and stop equalizations in both the manual and automatic mode Typical Equalizations The aut
42. currents exceeding the ratings of the product Unauthorized product modification or attempted repair Damage occurring during shipment 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 is authorized to make any modification or extension to this warranty MORNINGSTAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST PROFITS DOWNTIME GOODWILL OR DAMAGE TO EQUIPMENT OR PROPERTY 1098 Washington Crossing Road Washington Crossing PA 19877 USA Tel 215 321 4457 Fax 215 321 4458 Email info morningstarcorp com Website www morningstarcorp com 49 MORNINGSTAR CORPORATION 11 0 Technical Specifications ELECTRICAL e System voltage ratings 12 24 48 Vdc Current ratings Battery Charge Control TS 45 45A TS 60 60A Current ratings Load Control TS 45 45A TS 60 60A Current ratings Diversion Charge Control TS 45 45 A diversion load TS 60 60 A diversion load Accuracy 12 24V lt 0 1 26 50 mV 48V 0 1 100 mV Min voltage to operate 9V e Max solar array Voc 125 V e Max operating voltage 68 V Self consumption less than 20 mA High temp shutdown 95 C disconnect solar 90 C disc
43. e equalization will be terminated Note that if two or more TriStars are charging in parallel the equalization cycles may start on different days for various reasons such as one controller is disconnected and restarted If this happens the pushbutton on each controller can be used to manually start and then stop an equalization and this will reset the equalizations to the same schedule LOAD CONTROL PUSH Reset from an error or fault PUSH AND HOLD 5 SECONDS After a low voltage disconnect LVD of the load the pushbutton can be used to reconnect the loads again The loads will remain on for 10 minutes and will then disconnect again The pushbutton can be used to override the LVD without limit NOTE The purpose of the LVD is to protect the battery Repeated overrides of an LVD can deeply discharge the battery and may damage the battery 20 TRISTAR OPERATIO 3 3 LED Indications Valuable information can be provided by the three LED s in 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 or Load Status Faults LED Display Explanation G green LED is lit Y yellow LED is lit R red LED is lit G Y Green and Yellow are both lit at the same time G Y R Green amp Yellow both lit then Red is lit alone Sequencing faults has the LED pattern re
44. e much faster and the self discharging increases up to five times the initial rate as the battery ages Charging the antimony battery is typically from 14 4V to 15 0V with a 120 equalization overcharge While the water loss is low when the battery is new it will increase by five times over the life of the battery There are also combinations of plate chemistries that offer beneficial tradeoffs For example low antimony and selenium plates can offer fairly good cycling performance long life and reduced watering needs T NOTE Consult the battery manufacturer for the recommended solar charging settings for the battery being used 47 MORNINGSTAR CORPORATION 9 3 L 16 Cells One particular type of flooded battery the L 16 group is often used in larger solar systems The L 16 offers good deep cycle performance long life and low cost The L 16 battery has some special charging requirements in a solar system A study found that nearly half of the L 16 battery capacity can be lost if the regulation voltage is too low and the time between finish charges is too long One standard charging program in the TriStar is specifically for L 16 batteries and it provides for higher charging voltages and more frequent equalizations Additional equalizations can also be done manually with the pushbutton A good reference for charging L 16 batteries is a Sandia National Labs report year 2000 titled PV Hybrid Battery Tests on L 16 Batteries We
45. e that the battery voltage sense connection does not power start up the controller Step 6 System Wiring and Power Up To comply with the NEC the TriStar must be installed using wiring methods in accordance with the latest edition of the National Electric Code NFPA 70 Wire Size The four large power terminals are sized for 35 2 5 mm 2 14 AWG wire The terminals are rated for copper and aluminum conductors continued 15 MORNINGSTAR CORPORATION Wire Size continued Good system design generally requires large conductor wires for the solar and battery connections that limit voltage drop losses to 3 or less The following table provides the maximum wire length 1 way distance 2 wire pair for connecting the battery solar array or load to the TriStar with a maximum 3 voltage drop Wire Size 60 Amps 45 Amps 30 Amps 15 Amps 95 mm 12 86 m 17 15 m 25 72 m 51 44 m 3 0 AWG 42 2 ft 56 3 ft 84 4 ft 168 8 ft 70 mm 10 19 m 13 58 m 20 38 m 40 75 m 2 0 AWG 33 4 ft 44 6 ft 66 8 ft 133 7 ft 50 mm 8 10m 10 80 m 16 21 m 32 41 m 1 0 AWG 26 6 ft 35 4 ft 53 1 ft 106 3 ft 35 mm 5 12m 6 83m 10 24 m 20 48 m 2 AWG 16 8 ft 22 4 ft 33 6 ft 67 2 ft 25 mm 3 21m 4 27 m 6 41 m 12 82 m 4 AWG 10 5 ft 14 0 ft 21 0 ft 42 1 ft 16 mm2 2 02 m 2 69 m 4 04 m 8 07 m 6 AWG 6 6 ft 8 8 ft 13 2 ft 26 5 ft 10 mm 1 27 m 1 70 m 2 54 m 5 09 m 8 AWG
46. eck each switch position carefully TriStar has detected a fault indicated by sequencing LEDS refer to Section 3 3 Solar circuit breaker or disconnect is open Reversed polarity connections at the solar terminals TriStar will not detect the solar array Short circuit in the solar array has eliminated part of the array output Solar array is not providing enough current low sun or fault in the array Battery is failing and cannot hold a charge Troubleshooting Load Control No power to the load DIP switch settings may be wrong check each switch position carefully Controller is in LVD check the LEDs Load circuit breaker or disconnect may be open Check the load cables for continuity and good connection An over temperature condition may have caused the load to be disconnected Troubleshooting Diversion Control Diversion load is too small so PWM reaches 9996 Diversion load is burned out so PWM reaches 99 Diversion load is too large so TriStar faults on overcurrent An overtemperature condition may have caused the load to be disconnected The RTS is not correcting for high or low temperatures Voltage drops between the TriStar and battery are too high Still having problems Point your web browser to http www morningstarcorp com for technical support documents FAQS or to request technical support 45 MORNINGSTAR CORPORATION 9 0 Battery Information The standard battery charging
47. egulation voltage selected with the DIP switches plus the increase with an equalization plus the increase due to lower temperatures The highest battery voltage is commonly 15 30 and 60 volts for 12 24 and 48 volt systems Peak Load Current At the maximum battery voltage this is the current the diversion load will draw This peak load current must not exceed the TriStar s rating 7 NOTE Because the battery can supply any size load the peak load current is not limited by the source hydro or wind rating The diversion load s power rating is the critical specification for reliable battery charging 39 MORNINGSTAR CORPORATION 6 4 3 6 4 4 Load Power Ratings The power rating of the diversion load will depend on the voltage of the battery being charged If the heating element is not rated for the same voltage as the diversion system the power rating of the load must be adjusted to the diversion system s voltage The manufacturers typically rate the heating elements for power at a specified voltage The peak load current at the load s rated voltage will be the power divided by the rated voltage I P V For example 2000W 120V 16 7 amps of current If the load is being used at a voltage less than the load s rated voltage the power can be calculated by the ratio of the voltages squared For example a 120 volt 1000 watt heating element being used at 60 volts 1000W x 60 120 250 watts The 1000W element will on
48. ent or relocate the receiving antenna e 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 4 TRISTAR DESCRIPTION 1 6 Options Available Three optional components can be added to the standard TriStar controller at any time Remote Temperature Sensor RTS If the temperature of the system battery varies more than 5 C 9 F during the year temperature compensated charging should be considered Because the battery s chemical reactions change with temperature it can be important to adjust charging to account for the temperature effects The RTS will measure the battery temperature and the TriStar uses this input to adjust the charging as required The battery charging will be corrected for temperature as follows 12 V battery 0 030 Volts per C 0 017V per F 24 V battery 0 060 Volts per C 0 033V per F 48 V battery 0 120 Volts per C 0 067V per F The RTS should be used only for battery charging and diversion control Do not use the RTS for load control The charging parameters that are adjusted for temperature include PWM regulation Equalization e Float
49. etermine if the battery sense is working properly 3 5 Inspection and Maintenance The TriStar does not require routine maintenance The following inspections are recommended two times per year for best long term performance 1 Confirm the battery charging is correct for the battery type being used Observe the battery voltage during PWM absorption charging green LED 24 TRISTAR OPERATION blinking 1 2 second on 1 2 second off Adjust for temperature compensation if an RTS is used see Table 4 3 For load and diversion modes confirm that the operation is correct for the system as configured 2 Confirm the controller is securely mounted in a clean and dry environment 3 Confirm that the air flow around the controller is not blocked Clean the heat sink of any dirt or debris 4 Inspect for dirt nests and corrosion and clean as required 25 MORNINGSTAR CORPORATION 4 0 Solar Battery Charging 4 1 1 4 1 2 PWM Battery Charging PWM Pulse Width Modulation battery charging is the most efficient and effective method for recharging a battery in a solar system Refer to Why PWM on Morningstar s website for more information Selecting the best method for charging your battery together with a good maintenance program will ensure a healthy battery and long service life Although the TriStar s battery charging is fully automatic the following information is important to know for getting the best performance from
50. fasten the controller to the wall Provide for strain relief for the bottom knockouts if conduit will not be used Avoid excessive pulling forces on the terminals from the wires Step 3 Adjust the DIP Switches DT An 8 position DIP switch is used to set up the controller for its intended use All major functions can be set with the DIP switches See Section 7 0 for additional custom settings using PC software NOTE The instructions below are for solar battery charging Refer to Appendix 1 for Load Control DIP switch settings and Appendix 2 for Diversion Charge Control DIP switch settings The DIP switches are located behind the negative power terminals Each switch is numbered The solar battery charging functions that can be adjusted with the DIP switches follow ON ON DIP OFF 12345678 Control Mode Battery Charging 1 System Voltage 2 3 Battery Charging Algorithm 4 5 6 Battery Equalization 7 Noise Reduction 8 Figure 2 3 Step 3 DIP Switch Functions As shown in the diagram all the positions are in the OFF position except switch numbers 7 and 8 which are in the ON position NOTE The DIP switches should be changed only when there is no power to the controller Turn off disconnect switches and remove all power to the controller before changing a DIP switch A fault will be indicated if a switch is changed while the controller is powered 10 TRISTAR INSTALLATION CAUTION The TriStar is sh
51. fications subject to change without notice Designed in the U S A Assembled in Taiwan CE MS ZMAN TS01 A MAY 03 51 MORNINGSTAR CORPORATION Appendix 1 Load Control DIP Switch Settings The Load Control functions that can be adjusted with the DIP switches follow DIP IEEE oFF 1234 Control Mode DC Load Control 1 System Voltage 2 3 LVD LVDp 4 5 6 Not Used 7 Not Used 8 Figure 2 3 Step 3 Load DIP Switch Functions As shown in the diagram all the positions are in the OFF position except switch number 1 which is in the ON position NOTE The DIP switches should be changed only when there is no power to the controller Turn off disconnect switches and remove power to the controller before changing a DIP switch A fault will be indicated if a switch is changed with the controller powered up CAUTION The TriStar is shipped with all the switches in the OFF position Each switch position must be confirmed during installation A wrong setting could cause damage to the load or other system components The DIP switch settings described below are for Load Control only The DIP switches are shipped in the OFF position With switches 2 8 in the OFF position the following functions are present Switch Function 1 Must be ON for Load Control 2 3 Auto voltage select 4 5 6 Lowest LVD 11 1V 7 Not used selects diversion mode 8 Not used To configure your TriStar f
52. g Overload solar load R Y G sequencing Over temperature R Y sequencing High voltage disconnect R G sequencing Reverse polarity battery no LED s are lighted Reverse polarity solar No fault indication DIP switch fault R Y G sequencing Self test faults R Y G sequencing Temperature probe RTS R Y G Y sequencing Battery voltage sense R Y G Y sequencing 3 4 Protections and Fault Recovery The TriStar protections and automatic recovery are important elements of the operating system The system operator should be familiar with the causes of faults controller protections and any actions that may be required Some basic fault conditions are reviewed below Short circuit R G Y sequencing When a short circuit occurs the FET switches are opened in micro seconds The FETs will probably open before other protective devices in the system can react so the short circuit may remain in the system The TriStar will try to reconnect the FETs two times If the short circuit remains the LED s will continue sequencing After the short in the system is repaired there are two ways to restart the controller Power should have been disconnected to repair the short When power is restored the TriStar does a normal start up and will reconnect the solar input or load The pushbutton can also be used to reconnect the FET switches if there is battery power to the TriStar CP NOTE There will always be a
53. hen the battery is connected and the TriStar starts up There should be no loads on the battery that might cause a discharged battery to indicate a lower system voltage The DIP switch selectable voltages are for 12V 24V or 48V lead acid batteries Although the auto voltage selection is very dependable it is recommended to use the DIP switches to secure the correct system voltage DIP Switches Number 4 5 6 Battery Charging Algorithm Battery Type PWM Switch 4 Switch 5 Switch 6 1 14 0 Off Off Off 2 14 15 Off Off On 3 14 35 Off On Off 4 14 4 Off On On 5 14 6 On Off Off 6 14 8 On Off On 7 15 0 On On Off 8 Custom On On On ON I PWM 14 0V OFF PWM 14 15V PWM 14 35V PWM 15 0V PWM 14 4V Custom Figure 2 3 Step 3 DIP Switch 4 5 6 Select one of the 7 standard battery charging algorithms or select the custom DIP switch for special custom settings using the PC software Refer to Section 9 0 of this manual for battery charging information The 7 standard charging algorithms above are described in Section 4 2 Standard Battery Charging Programs DIP Switch Number 7 Battery Equalization Equalize Switch 7 Manual Off Auto On 12 TRISTAR INSTALLATION ON l Manual OFF In the Auto Equalization mode switch 7 On battery equalization will automatically start and stop according to the battery program selected by the DIP switches 4 5 6 above See Section 4 0 for detailed information
54. hort be certain to check for both shorts and reversed polarity connections If the controller does not go into short circuit protection the loads with polarity will be damaged CAUTION Carefully verify the polarity and of the load connections before applying power to the controller 36 LOAD CONTROL 6 0 Diversion Charge Control The TriStar s third mode of operation is diversion load battery charge control As the battery becomes fully charged the TriStar will divert excess current from the battery to a dedicated diversion load This diversion load must be large enough to absorb all the excess energy but not too large to cause a controller overload condition 6 1 Diversion Charge Control In the diversion mode the TriStar will use PWM charging regulation to divert excess current to an external load As the battery becomes fully charged the FET switches are closed for longer periods of time to direct more current to the diversion load As the battery charges the diversion duty cycle will increase When fully charged all the source energy will flow into the diversion load if there are no other loads The generating source is typically a wind or hydro generator Some solar systems also use diversion to heat water rather than open the solar array and lose the energy The most important factor for successful diversion charge control is the correct sizing of the diversion load If too large the controller s protections may
55. hout this manual The TriStar is suitable for a wide range of solar applications including homes telecom and industrial power needs TriStar controllers are configured for negative ground systems There are no parts in the controller s negative leg The enclosure can be grounded using the ground terminal in the wiring compartment The TriStar is protected from faults electronically with automatic recovery There are no fuses or mechanical parts inside the TriStar to reset or change Solar overloads up to 130 of rated current will be tapered down instead of disconnecting the solar Over temperature conditions will also taper the solar input to lower levels to avoid a disconnect The NEC requires overcurrent protection externally in the system see Section 2 3 step 6 There are no system disconnects inside the TriStar enclosure Any number of TriStars can be connected in parallel to increase solar charging current TriStars can be paralleled ONLY in the battery charging mode DO NOT parallel TriStars in the load mode as this can damage the controller or load The TriStar enclosure is rated for indoor use The controller is protected by conformal coated circuit boards stainless steel hardware anodized aluminum and a powder coated enclosure but it is not rated for corrosive environments or water entry The construction of the TriStar is 100 solid state Battery charging is by a series PWM constant current charging with bulk ch
56. ies If the solar array exceeds the current rating of the controller multiple TriStars can be installed in parallel Additional parallel controllers can also be added in the future The load controllers cannot be used in parallel To parallel diversion controllers refer to Morningstar s website If solar charging and load control are both required two separate controllers must be used n Overview Installat The installation is straightforward but it is important that each step is done correctly and safely A mistake can lead to dangerous voltage and current levels Be sure to carefully follow each instruction in Section 2 3 and observe all cautions and warnings The following diagrams provide an overview of the connections and the proper order Load A or Solar Load Solar Load Figure 2 2a Installation Wiring for Solar Charging and Load Control 6 TRISTAR INSTALLATION Step Solar Charging and Load Control 1 Remove the access cover 2 Mount the TriStar using the enclosed template 3 Adjust the 8 switches in the DIP switch Each switch must be in the correct position 4 Attach the RTS if battery charging will be temperature compensated not for load control 5 Connect battery voltage sense wires recommended 6 Connect the battery power wires to the TriStar Then connect the solar array wires or load 7 Connect a computer to the TriStar if making adjustments w
57. ing LEDs Reference Section 3 3 for a list of LED indications and their corresponding faults alarms Self Test Indication R Y G sequencing Self testing will also detect various system wiring faults outside the TriStar Check for both TriStar faults and external system wiring problems The RTS or Battery Sense is not working properly e R Y G Y sequencing LEDs indicates an RTS or Sense fault Check for a reverse polarity connection on the sense leads Verify that the RTS and Sense connections are wired to the correct terminals Check for shorts and continuity in the cables Verify that good electrical contact is made at the terminals Note that if the TriStar is restarted with an RTS or Sense fault present it will not detect the RTS or Sense connection and the LED indication will stop Troubleshooting Solar Charging Over charging or under charging the battery DIP switch settings may be wrong RTS is not correcting for high or low temperatures Over temperature condition is reducing the charging current heat sink cooling may be blocked indicated with LED s Voltage drop between TriStar and battery is too high connect the battery voltage sense see Section 2 3 Step 5 44 SELF TESTING DIAGNOSTICS Battery charging requires temperature compensation connect a remote temperature sensor Load is too large and is discharging the battery Not charging the battery DIP switch settings may be wrong ch
58. ipped with all the switches in the OFF position Each switch position must be confirmed during installation A wrong setting could cause damage to the battery or other system components The DIP switch settings described below are for Solar Battery Charging only Load and Diversion switch settings can be found in Appendixes 1 and 2 The DIP switches are shipped in the OFF position With the switches in the OFF position the following functions are present Switch Function 1 Battery charge mode 2 3 Auto voltage select 4 5 6 Lowest battery charging voltage 7 Manual equalization 8 Normal PWM charging mode To configure your TriStar for the battery charging and control you require follow the DIP switch adjustments described below To change a switch from OFF to ON slide the switch up toward the top of the controller Make sure each switch is fully in the ON or OFF position DIP Switch Number 1 Control Mode Solar Battery Charging Control Switch 1 Charging Off Load On ON ON DIP ELLE OFF Figure 2 3 Step 3 DIP Switch 1 H 45678 For the Solar Battery Charging control mode leave the DIP switch in the OFF position as shown DIP Switches Number 2 3 System Voltage Voltage Switch 2 Switch 3 Auto Off Off 12 Off On 24 On Off 48 On On ON l Auto Select 24 Volts OFF 12 Volts 48 Volts Figure 2 3 Step 3 DIP Switches 2 3 11 MORNINGSTAR CORPORATION The auto voltage selection occurs w
59. ith PC software 8 Replace the cover Steps 3 and 6 are required for all installations Steps 4 5 and 7 are optional Diversion Source Source Diversion Figure 2 2b Installation Wiring for Diversion Charge Control Step Diversion Charge Control 1 Remove the access cover 2 Mount the TriStar using the enclosed template 3 Adjust the 8 switches in the DIP switch Each switch must be in the correct position 4 Attach the RTS if battery charging will be temperature compensated Connect battery voltage sense wires recommended 6 Connect the battery power wires to the TriStar Then connect the diversion load wires gi continued 7 MORNINGSTAR CORPORATION Step Diversion Charge Control continued 7 Connect a computer to the TriStar if making adjustments with PC software 8 Replace the cover Steps 3 and 6 are required for all installations Steps 4 5 and 7 are optional 2 3 Installation Steps The TriStar controller must be installed properly and in accordance with the local and national electrical codes It is also important that the installation be done safely correctly and completely to realize all the benefits that the TriStar can provide for your solar system Refer to Sections 4 0 and 9 0 for information about the TriStar s standard battery charging programs and general charging needs for different battery types Refer to Section 5 0 for lo
60. le means for grounding shall be provided The clamping of the earthing shall be secured against accidental loosening The entry openings to the TriStar wiring compartment shall be protected with conduit or with a bushing FCC requirements This device complies with Part 15 of the FCC rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation Changes or modifications not expressly approved by Morningstar for compliance could void the user s authority to operate the equipment Note This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communication However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment on and off the user is encouraged to try to correct the interference by one or more of the following measures Reori
61. long controlled overcharge or equalization at a higher voltage can reverse the hardening sulfate crystals In addition to slowing or preventing lead sulfation there are also other benefits from equalizations of the solar system battery These include Balance the individual cell voltages Over time individual cell voltages can drift apart due to slight differences in the cells For example in a 12 cell 24V battery one cell is less efficient in recharging to a final battery voltage of 28 8 volts 2 4 V c Over time that cell only reaches 1 85 volts while the other 11 cells charge to 2 45 volts per cell The overall battery voltage is 28 8V but the individual cells are higher or lower due to cell drift Equalization cycles help to bring all the cells to the same voltage Mix the electrolyte In flooded batteries especially tall cells the heavier acid will fall to the bottom of the cell over time This stratification of the electrolyte causes loss of capacity and corrosion of the lower portion of the plates Gassing of the 30 SOLAR BATTERY CHARGING 4 4 1 4 4 2 4 4 3 electrolyte from a controlled overcharging equalization will stir and remix the acid into the battery electrolyte NOTE Excessive overcharging and gassing too vigorously can damage the battery plates and cause shedding of active material from the plates An equalization that is too high or for too long can be damaging Review the requirements for the parti
62. ly dissipate 250W when being used at 60 volts NOTE The loads heating elements can be used at the manufacturer s voltage rating or at a lower voltage Do not use the load at a higher voltage than the load s rating Maximum Diversion Load The diversion load should never exceed the TriStar s current rating 45A or 604 Note that the load is not limited by the source wind hydro and will draw its rated current from the battery The following table specifies the absolute maximum diversion loads that can be used with each TriStar version These loads heating elements are rated for the same voltage as the system voltage Nominal Voltage TriStar 45 TriStar 60 48V 2700W at 60V 3600W at 60V 24V 1350W at 30V 1800W at 30V 12V 675W at 15V 900W at 15V These maximum power ratings are translated to the equivalent at 120 volts in the following table If using heating elements rated for 120 volts the power ratings of all the elements can be simply added up and the sum compared with this table and no further math is required Nominal Voltage TriStar 45 TriStar 60 48V 10 800W at 120V 14 400W at 120V 24V 21 600W at 120V 28 800W at 120V 12V 43 200W at 120V 57 600W at 120V To illustrate the same point from the opposite perspective a heating element rated for 120 volts will draw reduced load current as indicated by the following table A standard 2 000 watt 120 Vac heating element is used as the reference 40 DIVERSI
63. m over discharge with a current compensated LVD low voltage load disconnect Diversion charge control In diversion mode the TriStar will manage battery charging by diverting energy from the battery to a dedicated diversion load The energy source is typically wind or hydro 1 3 Adjustability Eight DIP switches permit the following parameters to be adjusted at the installation site DIP switch Solar Battery Charging 1 Battery charge control mode 2 3 Select battery voltage 4 6 Standard battery charging programs 7 Manual or automatic equalization 8 PWM charging or on off charging DIP switch Load Control 1 DC load control mode 2 3 Select battery voltage 4 6 Standard low voltage disconnects and reconnects 7 not used for load control 8 not used for load control DIP switch Diversion Charge Control 1 DC load control mode 2 3 Select battery voltage 4 6 Standard diversion charge control programs 7 Select diversion charge control mode 8 Manual or automatic equalization In addition to the DIP switches the TriStar provides for additional adjust ments using a PC program An RS 232 connection between the TriStar and a personal computer will enable extensive adjustments using PC software from Morningstar s website 2 TRISTAR DESCRIPTION 1 4 General Use gt NOTE This manual describes solar battery charging Specific instructions for the load control and diversion charge control modes are provided as notes throug
64. n Voltage During an equalization cycle the charging voltage will be held constant at this voltage Equalizations are manual and can be selected for automatic See Section 4 4 1 E Time in Equalization Charging at the selected equalization voltage will continue for this number of hours F Equalization Interval Equalizations are typically done once a month The cycles are 28 days so the equalization will begin on the same day of the week Each new cycle will be reset as the equalization starts so that a 28 day period will be maintained G Maximum Equalization Cycle If the battery voltage cannot reach the equalization voltage the equalization will terminate after this number of hours to avoid over gassing or heating the battery If the battery requires more time in equalization the manual pushbutton can be used to continue for one or more additional equalization cycles Battery Charging References The diversion load battery charging is similar to conventional solar charging Refer to the following sections in this manual for additional battery charging information 4 1 Four stages of charging applies to diversion 4 3 Temperature Effects and Battery Voltage Sense 38 DIVERSION CHARGE CONTROL 4 4 Equalization 4 5 Float 9 0 Battery Information 6 4 Selecting the Diversion Load It is critical that the diversion load be sized correctly If the load is too small it cannot divert enough power from the source wind hydro e
65. n stage to be 14 2V and 14 4V 12V battery The 14 0 14 2 and 14 4 volt standard charging programs should be suitable for most sealed batteries If not optimum for your battery the PC software can be used to adjust these values Refer to Section 9 0 for more information about charging sealed batteries When a battery becomes fully charged dropping down to the float stage will provide a very low rate of maintenance charging while reducing the heating and gassing of a fully charged battery When the battery is fully recharged there can be no more chemical reactions and all the charging current is turned into heat and gassing 32 SOLAR BATTERY CHARGING The purpose of float is to protect the battery from long term overcharge From the PWM absorption stage charging is dropped to the float voltage This is typically 13 4V and is adjustable with the PC software The transition to float is based on the previous 24 hour history Factors include the battery voltage the state of charge the night before the battery type and the PWM duty cycle and stability of the duty cycle The battery will be charged for part of the day until the transition to float If there are loads for various periods of time during float the TriStar will cancel float and return to bulk charge Float is temperature compensated 33 MORNINGSTAR CORPORATION 5 0 Load Control This section describes the user selectable load control settings 5 1 and the low volt
66. omatic equalizations will occur every 28 days except L 16 cells at 14 days When an equalization begins auto or manual the battery charging voltage increases up to the equalization voltage Veq The battery will remain at Veq for the time specified in the selected charging program see table in 4 2 If the time to reach Veq is too long the maximum equalization cycle time will end the equalization A second manual equalization cycle can be started with the pushbutton if needed If the equalization cannot be completed in one day it will continue the next day or days until finished After an equalization is completed charging will return to PWM absorption Preparation for Equalization First confirm that all your loads are rated for the equalization voltage Consider that at 0 C 32 F the equalization voltage will reach 16 05V in a 12V continued 31 MORNINGSTAR CORPORATION 4 4 3 4 4 4 4 4 5 Preparation for Equalization continued a 12V system 64 2V in a 48V system with a temperature sensor installed Disconnect any loads at risk If Hydrocaps are used be sure to remove them before starting an equal ization Replace the Hydrocaps with standard battery cell caps The Hydro caps 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 gassing lo
67. onnect load diversion load 70 C reconnect solar load diversion load Solar high voltage disconnect highest equalization 0 2V HVD reconnect 13 0V Transient surge protection pulse power rating 4500 watts response 5 nanosec BATTERY CHARGING RTS Charge algorithm PMW constant voltage Temp comp coefficient 5mV C cell 25 C ref Temp comp range 30 C to 80 C Temp comp setpoints PWM float equalize HVD with RTS option BATTERY CHARGING STATUS LED s G 13 3 to PWM GY 130to 13 3 V Y 12 65 to 13 0 V Y R 12 0 to 12 65 V R Oto120V Note Multiply x 2 for 24V systems x 4 for 48V systems Note The LED indications are for charging a battery When discharging the LED s will typically be Y R or R 50 TECHNICAL SPECIFICATIONS MECHANICAL e Dimensions mm inch Weight kg Ib Power terminals largest wire smallest wire Terminal wire slot e Knockout sizes Torque terminals e RTS Sense terminals wire sizes torque ENVIRONMENTAL Ambient temperature Storage temperature Humidity Enclosure H 260 4 mm 10 25 inch W 127 0 mm 5 0 inch D 71 0 mm 2 8 inch 1 6 kg 3 5 Ib compression connector lug 35 mm 2 AWG 2 5 mm 14 AWG 8 2 mm 0 324 in wide 9 4 mm 0 37 in high 1 and 1 25 inch 5 65 Nm 50 in lb 1 0 to 0 25 mm 16 to 24 AWG 0 40 Nm 3 5 in Ib 40 to 45 C 55 to 85 C 10096 NC Type 1 Indoor amp vented powder coated steel Speci
68. or the Load Control you require follow the DIP switch adjustments described below To change a switch from OFF to ON slide the switch up toward the top of the controller Make sure each switch is fully in the ON or OFF position 52 APPENDIX I DIP Switch Number 1 Control Mode Load Control Control Switch 1 Charging Off Load Figure 2 3 Step 3 DIP Switch 1 For the Load Control mode move the DIP switch to the ON position as shown DIP Switches Number 2 3 System Voltage Voltage Switch 2 Switch 3 Auto Off Off 12 Off On 24 On Off 48 On On ON ON DIP l Auto Select p f f p f f 24 Volts OFF M2 AAS WOMETING 12 Volts 48 Volts Figure 2 3 Step 3 DIP Switches 2 3 The auto voltage selection occurs when the battery is connected and the TriStar starts up There should be no loads on the battery that might cause a discharged battery to indicate a lower system voltage The DIP switch selectable voltages are for 12V 24V or 48V lead acid batteries Although the auto voltage selection is very dependable it is recommended to use the DIP switches to secure the correct system voltage DIP Switches Number 4 5 6 Load Control Algorithm LVD Switch 4 Switch 5 Switch 6 11 1 Off Off Off 11 3 Off Off On 11 5 Off On Off 11 7 Off On On 11 9 On Off Off 12 1 On Off On 12 3 On On Off Custom On On On gt x S 2 2 wn 53 MORNINGSTAR CORPORATION ON I LVD 11 1V LVD 11 9V OFF
69. out There is also a potential for thermal runaway if the battery gets too hot and this will destroy the battery AGM batteries are affected by heat and can lose 50 of their service life for every 8 C 15 F over 25 C 77 F It is very important not to exceed the gas recombination capabilities of the AGM The optimum charging temperature range is from 5 to 35 C 40 to 95 F Gel Gel batteries have characteristics similar to AGM except a silica additive immobilizes the electrolyte to prevent leakage from the case And like AGM it is important to never exceed the manufacturer s maximum charging voltages Typically a gel battery is recharged in cycling applications from 14 1V to 14 4V The gel design is very sensitive to overcharging For both AGM and Gel batteries the goal is for 100 recombination of gasses so that no water is lost from the battery True equalizations are never done but a small boost charge may be needed to balance the individual cell voltages 46 BATTERY INFORMATION Other Sealed Batteries Automotive and maintenance free batteries are also sealed However these are not discussed here because they have very poor lifetimes in solar cycling applications NOTE Consult the battery manufacturer for the recommended solar charging settings for the battery being used 9 2 Flooded Batteries Flooded vented batteries are preferred for larger cycling solar systems The advantages of flooded batteries in
70. peating until the fault is cleared 1 General Transitions Controller start up G Y R one cycle Pushbutton transitions blink all 3 LED s 2 times e Battery service is required all 3 LED s blinking until service is reset 2 Battery Status General state of charge see battery SOC indications below PWM absorption G blinking 1 2 second on 1 2 second off Equalization state G fast blink 2 to 3 times per second Float state G slow blink 1 second on 1 second off Battery State of Charge LED Indications when battery is charging eGon 80 to 95 SOC G Y on 6096 to 8096 SOC Y on 35 to 60 SOC e Y R on 0 to 35 SOC e Ron battery is discharging Refer to the Specifications Section 11 0 for the State of Charge voltages Another LED chart is provided at the end of this manual Appendix 3 for easier reference 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 LOAD CONTROL 2 Load Status 12V 24V 48V BD 0 60V AOV 2 40V LVD 0 45V 0 90V 1 80V LVD 0 30V 0 60V 1 20V LIVD OSV SON O The load status LED s are determined by the LVD voltage plus the specified transition voltages As the battery voltage rises or falls each voltage transition will cause a change in the LED s 21 MORNINGSTAR CORPORATIO 3 Faults amp Alarms Short circuit solar load R G Y sequencin
71. programs in the TriStar controller as described in Section 4 2 are typical charging algorithms for three battery types e sealed VRLA e flooded vented e L 16 group Other battery chemistries such as NiCad or special voltages such as 36V can be charged using a custom charging algorithm modified with the PC software Only the standard TriStar battery charging programs will be discussed here CAUTION Never attempt to charge a primary non rechargeable battery All charging voltages noted below will be for 12V batteries at 25 C Sealed Batteries The general class of sealed batteries suitable for solar systems are called VRLA Valve Regulated Lead Acid batteries The two main characteristics of VRLA batteries are electrolyte immobilization and oxygen recombination As the battery recharges gassing is limited and is recombined to minimize the loss of water The two types of VRLA batteries most often used in solar are AGM and Gel AGM Absorbed Glass Mat batteries are still considered to be a wet cell because the electrolyte is retained in fiberglass mats between the plates Some newer AGM battery designs recommend constant voltage charging to 2 45 volts cell 14 7V For cycling applications charging to 14 4V or 14 5V is often recommended AGM batteries are better suited to low discharge applications than daily cycling These batteries should not be equalized since gassing can be vented which causes the battery to dry
72. ption G blinking 1 2 second on 1 2 second off Equalization state G fast blink 2 to 3 times per second Float state G slow blink 1 second on 1 second off Battery State of Charge LED Indications when battery is charging eGon 80 to 95 SOC G Y on 6096 to 8096 SOC Yon 35 to 60 SOC e Y R on 0 to 35 SOC Ron battery is discharging LOAD CONTROL 2 Load Status 12V 24V 48V LVD 0 60V 1 20V 2 40V LVD 0 45V 0 90V 1 80V LVD 0 30V 0 60V 1 20V R Blinkina D 0 15V 0 30V O 60V R LVD The load status LED s are determined by the LVD voltage plus the specified transition voltages As the battery voltage rises or falls each voltage transition will cause a change in the LED s 3 Faults amp Alarms Short circuit solar load R G Y sequencing Overload solar load R Y G sequencing Over temperature R Y sequencing High voltage disconnect R G sequencing e Reverse polarity battery no LEDs are lighted Reverse polarity solar No fault indication DIP switch fault R Y G sequencing Self test faults R Y G sequencing Temperature probe RTS R Y G Y sequencing Battery voltage sense R Y G Y sequencing 59 MORNINGSTAR CORPORATION gt x 53 Q a wn
73. r dc motors and other inductive loads it is strongly recommended to install a diode near the controller Inductive loads can generate large voltage spikes that might damage the controller s lightning protection devices The diode should be installed near the controller and in the orientation shown in the diagram on the next page 35 MORNINGSTAR CORPORATION 5 4 1 5 4 2 5 4 3 Figure 5 3 Diode Protection The specifications for the diode follow a power diode rated equal or greater than 80 volts rated equal or greater than 45 amps TS 45 or 60 amps TS 60 For large inductive loads a heat sink for the diode may be necessary General Load Control Notes In addition to the inductive loads discussed above there are a few other load issues that require attention Inverters Inverters should never be connected to the TriStar Parallel TriStars Two or more TriStars should never be put in parallel for a large load The controllers cannot share the load Reverse Polarity If the battery is correctly connected LEDs are on the load should be connected very carefully with regard to polarity If the polarity is reversed the controller cannot detect this There are no indications Loads without polarity will not be affected Loads with polarity can be damaged It is possible that the TriStar will go into short circuit protection before the load is damaged If the LEDs indicate a s
74. re suitable for a wide range of lead acid battery types These standard programs are reviewed in the following Section 4 2 A general review of battery types and their charging needs is provided in Section 9 0 Standard Battery Charging Programs The TriStar provides 7 standard battery charging algorithms programs that are selected with the DIP switches see Step 3 in Installation These standard algorithms are suitable for lead acid batteries ranging from sealed gel AGM maintenance free to flooded to L 16 cells In addition an 8th DIP switch provides for custom setpoints using the PC software The table below summarizes the major parameters of the standard charging algorithms Note that all the voltages are for 12V systems 24V 2X 48V 4X All values are 25 C 77 F A B C D E F G DIP PWM Time Equalize Max Equal Switches Battery Absorp Float Equal in Equal Interval Cycle 4 5 6 Type Voltage Voltage Voltage hours days hours off off off 1 Sealed 14 0 13 4 none off of on 2 Sealed 14 15 13 4 14 2 1 28 1 off on off 3 Sealed 14 35 13 4 14 4 2 28 2 offon on 4 Flooded 14 4 13 4 15 1 3 28 4 on off off 5 Flooded 14 6 13 4 15 3 3 28 5 on off on 6 Flooded 14 8 13 4 15 3 3 28 5 on on off 7 L 16 15 0 13 4 15 3 3 14 5 on on on 8 Custom Custom Custom Table 4 2 Standard Battery Charging Programs A Battery Type These are generic lead acid battery types See Section 9 0 for more information about
75. s 48 Volts Figure 2 3 Step 3 DIP Switches 2 3 The auto voltage selection occurs when the battery is connected and the TriStar starts up There should be no loads on the battery that might cause a discharged battery to indicate a lower system voltage The DIP switch default voltages are for 12V 24V or 48V lead acid batteries Although the auto voltage selection is very dependable it is recommended to use the DIP switches to secure the correct system voltage DIP Switches Number 4 5 6 Diversion Charge Control Battery Type PWM Switch 4 Switch 5 Switch 6 1 13 7 Off Off Off 2 13 9 Off Off On 3 14 1 Off On Off 4 14 3 Off On On 5 14 5 On Off Off 6 14 7 On Off On 7 14 9 On On Off 8 Custom On On On 56 APPENDIX II ON I DIV 13 7V DIV 14 5V OFF DIV 13 9V DIV 14 7V DIV 14 1V DIV 14 9V DIV 14 3V Custom Figure 2 3 Step 3 DIP Switches 4 5 6 Select one of the 7 standard diversion charging algorithms or select the custom DIP switch for special custom settings using the PC software Refer to Section 6 3 for information describing the 7 standard diversion charging algorithms Refer to Section 9 0 of this manual for battery charging information DIP Switch Number 7 Select Diversion Switch 7 OFF In the Diversion Charge Control mode DIP switch 7 must be in the ON position DIP Switch Number 8 Battery Equalization Equalize Switch 8 Manual Off Auto On ON li Manual OFF Automa
76. sses Check that the battery plates are covered 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 to equalize 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 Equalize a Sealed Battery The standard battery charging table see Section 4 2 shows two sealed batteries with an equalization cycle This is only a 0 05 volt 12V battery boost cycle 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 This boost charge for sealed cells allows for adjustability with the PC software Many VRLA batteries including AGM and gel have increased charging requirements up to 14 4V 12V battery The 0 05V boost shown in the table Section 4 2 is less than the accuracy range of most charge controllers Alternatively for these two sealed battery charging programs you may prefer to consider the PWM absorptio
77. tc The battery will continue charging and could be overcharged If the diversion load is too large it will draw more current than the rating of the TriStar The controller s overload protection may disconnect the diversion load and this will result in all of the source current going to the battery CAUTION The diversion load must be able to absorb the full power output of the source but the load must never exceed the current rating of the TriStar controller Otherwise the battery can be overcharged and damaged 6 4 1 Suitable Loads for Diversion Water heating elements are commonly used for diversion load systems These heating elements are reliable and widely available Heating elements are also easy to replace and the ratings are stable NOTE Do not use light bulbs motors or other electrical devices for diversion loads These loads will fail or cause the TriStar to disconnect the load Only heating elements should be used Water heating elements are typically 120 volts Elements rated for 12 24 and 48 volts are also available but more difficult to source The derating for 120 volt heating elements is discussed in 6 4 3 below 6 4 2 Definition of Terms Maximum Source Current This is the maximum current output of all the energy sources hydro wind solar etc added together This current will be diverted through the TriStar to the diversion load Maximum Battery Voltage This maximum voltage is the PWM r
78. ted above by the following values e 12 volt battery 0 030 volts per C 0 017 volts per F e 24 volt battery 0 060 volts per C 0 033 volts per F e 48 volt battery 0 120 volts per C 0 067 volts per F Variations in battery temperature can affect charging battery capacity and battery life The greater the range of battery temperatures the greater the impact on the battery For example if the temperature falls to 10 C 50 F this 15 C 27 F change in temperature will change the PWM equalization and float setpoints by 1 80V in a 48V system If a remote temperature sensor is not used and the temperatures near the battery are stable and predictable the PWM absorption setting can be adjusted using the PC software per the following table Temperature 12 Volt 24 Volt 48 Volt 40 C 104 F 045V 090V 1 80V 35 C 95 F 030V 0 60V 120V 30 C 86 F 0 15V 0 30V 0 60V 29 CH TEE 0v 0v 0v 20 C 68 F 0 15V 0 30V 0 60V 15 C 59 9F 0 30V 060V 1 20V 10 C 50 F 045V 090V 1 80V 5 C 41 F 060V 1 20V 2 40V O C 32 F 0 75V 1 50V 3 00V 5 C 23 F 090V 180V 3 60V 10C 14F 1 05V 210V 4 20V 15C 5bF 120V 240V 480V Table 4 3 Temperature Compensation 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 gassing too much or not charging enough an RTS can
79. tic gt x 2 E 2 wn Figure 2 3 Step 3 DIP Switch 8 57 MORNINGSTAR CORPORATION In the Auto Equalization mode switch 48 On battery equalization will automatically start and stop according to the battery program selected by the DIP switches 4 5 6 above See Section 6 0 for detailed information about each standard diversion battery charging algorithm and equalization In the Manual Equalization mode switch 8 Off equalization will occur only when manually started with the pushbutton Automatic starting of equalization is disabled The equalization will automatically stop per the battery algorithm selection In both cases auto and manual mode the pushbutton can be used to start and stop battery equalization x NOTE Confirm all dip switch settings before going to the next installation steps 58 APPENDIX II Appendix 3 LED Indications LED Display Explanation G green LED is lit Y yellow LED is lit R red LED is lit G Y Green and Yellow are both lit at the same time G Y R Green amp Yellow both lit then Red is lit alone Sequencing faults has the LED pattern repeating until the fault is cleared 1 General Transitions Controller start up G Y R one cycle Pushbutton transitions blink all 3 LED s 2 times e Battery service is required all 3 LED s blinking until service is reset 2 Battery Status General state of charge see battery SOC indications below PWM absor
80. urrent by regulating the current to safe levels If the current from the solar array exceeds 130 the controller will interrupt charging see Section 3 4 26 SOLAR BATTERY CHARGING Battery Voltage Sense Connecting a pair of voltage sense wires from the controller to the battery is recommended This allows a precise battery voltage input to the controller and more accurate battery charging See Section 4 3 for more information Temperature Compensation All charging setpoints are based on 25 C 77 F If the battery temperature varies by 5 C the charging will change by 0 15 volts for a 12 volt battery This is a substantial change in the charging of the battery and a remote temperature sensor is recommended to adjust charging to the actual battery temperature See Section 4 3 for more information Day Night Detection The TriStar will automatically detect day and night conditions Any functions that require measuring time or starting at dawn for example will be automatic PWM Noise In some installations the PWM charging may cause audible noise in certain equipment If this occurs the PWM can be changed to On Off solar charging to reduce the noise This requires DIP switch number 8 to be turned On However it is strongly recommended to try to remedy the noise problem with grounding or filtering first because the benefits from PWM battery charging are significant Battery Types The TriStar s standard battery charging programs a
81. your TriStar controller and battery Four Stages of Solar Charging 1 1 PWM 4 BULK ABSORPTION m NIGHT CHARGING NIGHT Figure 4 1 1 Solar Charging Stages 2 1 Bulk Charging In this stage the battery will accept all the current provided by the solar system The LED s will display an indication of the battery charge state as the battery is being recharged 2 PWM Absorption When the battery reaches the regulation voltage the PWM begins to hold the voltage constant This is to avoid over heating and over gassing the battery The current will taper down to safe levels as the battery becomes more fully charged The green LED will blink once per second See Section 4 2 3 Equalization Many batteries benefit from a periodic boost charge to stir the electrolyte level the cell voltages and complete the chemical reactions The green LED will blink rapidly 2 3 times per second See Section 4 4 4 Float When the battery is fully recharged the charging voltage is reduced to prevent further heating or gassing of the battery The green LED will blink slowly once every 2 seconds See Section 4 5 Battery Charging Notes The TriStar manages many different charging conditions and system configu rations Some useful functions to know follow below Solar Overload Enhanced radiation or edge of cloud effect conditions can generate more current than the controller s rating The TriStar will reduce this overload up to 13096 of rated c

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