- What is PWM charging? PWM is an acronym for Pulse Width Modulation. When the
battery is recharged to regulation voltage, the controller will begin limiting
the amount of current into the battery so that the regulation voltage is maintained
but not surpassed. The method of regulating the current, referred to as PWM,
pulses current into the battery with pulses of a varying width. Wider pulses
allow a greater percentage of the input current to flow into the battery,
narrower pulses restrict current to a lower percentage. Refer to the document,
"Why PWM?" for more technical and
detailed information concerning PWM charging.
- What is the purpose of the "Load" connection?
The Load connection allows the user to wire DC devices such as fans, bulbs,
or communication equipment directly to the controller. This allows the controller
to disconnect the loads if necessary for protection of the controller, battery,
or the loads themselves. This connection is optional.
- Can I wire multiple controllers to the same battery
bank?
Yes. There can be as many Morningstar controllers as required in parallel
on the same battery bank.
- Can I use a power source other than a PV panel
to charge my batteries? We do not recommend using a DC power supply with any of our controllers. While they appear to be similar to PV modules in function, DC power supplies provide a constant current source into the controller. They cannot be open-circuited in the way a solar module can. Connecting a DC power supply to our controllers can cause them to heat up significantly and could lead to premature failure. If you need to provide a second charging source to a battery, make sure it is a source designed specifically for battery charging that can intelligently regulate on its own (a battery charger and not just a power supply only). This can then be connected in parallel to the battery.
- How do I calculate the effect of temperature compensation
on the regulation voltage?
Refer to the document, "Temperature Compensation Charts"
which includes compensation curves for all Morningstar Controllers.
- Do Morningstar Controllers regulate according
to SOC calculations?
No. Morningstar Controllers regulate according to battery voltage setpoints.
Because battery health and other factors affect charging over time, using
voltage setpoints is a way to naturally track these changes and affords the
user a complete understanding of the controllers operation. SOC calculations
and algorithms may not be precise under all conditions and may leave the user
with a "fuzzy" understanding of the workings of the unit.
- Can I wire multiple controllers in parallel off
the same PV array to charge different batteries?
Yes. Refer to the document, "Charging Isolated Battery
Banks".
- Can I parallel the load output of multiple controllers
to drive higher current loads?
No. Since the controllers will not reach LVD at exactly the same moment, some
controllers may carry the full load after others have already reached LVD.
During this time, a significant over-current will damage the Load side of
those controllers.
- What are the functions of the TriStar?
The TriStar can function as a solar charge controller, a load controller, OR a diversion controller. It can be configured to perform ONLY ONE function at a time.
- How much current does the TriStar consume? What is its self-consumption current?
The TriStar will consume less than 20mA. The digital meter and other options may increase consumption.
- What is the method of regulation?
The TriStar uses PWM (pulse width modulation) regulation. There is a DIP switch option to change the regulation method to On-Off to reduce noise in telecom applications. This method switches at 1Hz and is less efficient than PWM. We recommend the PWM setting unless there are issues with noise.
- I sometimes hear a buzzing noise during charging. Is something wrong?
No. The buzzing sound is mechanical resonance created by the switching of current through the circuit board and solid-state devices. This is normal and not indicative of a problem.
- Does the TriStar have any internal fuses?
There are no internal fuses in the TriStar. Short-circuit and over-current protections are electronic.
- What is the purpose of the Battery Sense connection?
When large currents flow through the battery power cables, a voltage drop results due to resistance in the cables. Since the TriStar regulates the batteries according to battery voltage, it is important that the TriStar measure the voltage directly at the battery. The Battery Sense connection allows battery voltage measurement directly at the terminals because the sense lines carry very little current (hence, small-gauge wire), enabling accurate regulation.
Without the sense lines, the TriStar must use the battery power connections, which may be different than actual battery voltage. The Battery Sense connection is optional and is only needed when significant voltage drops exist on the battery power cables.
- Will the TriStar perform lighting control?
Yes. While it is not documented in the user manual, the TriStar is capable of lighting control. Lighting control must be configured in the custom settings. For more information, download the TriStar Lighting Control document.
- What happens if I exceed the TriStar current rating?
The TriStar has over-current protections built in, and will set an alarm and/or fault if the condition persists. The controller will limit input/load current to prevent damage and in severe cases, will switch off the current. Never design a system where the current will exceed the controller's rating under normal system conditions. Systems designed to NEC standards must follow the current de-rating guidelines (as outlined in the user manual)
- The LEDs are flashing and/or my meter reports Faults or Alarms. Where can I find detailed information concerning these errors?
The TriStar Operation Manual provides detailed explanations concerning the flashing LED sequences that occur when a fault is present. The TriStar Digital Meter Installation and Operation Manual provides definitions for each of the faults and alarms displayed in the Diagnostics menu.
- The meter is reporting voltage/current values that are higher or lower than the actual values. What's wrong?
Measure the voltages directly at the TriStar terminals. Voltage drops due to line resistances can be significant.
Be sure the Battery Sense wires are not wired to the RTS(remote temperature sensor) terminals. Both terminals look similar and are easy to mix up.
Check for correct polarity at the Battery Sense connection.
Confirm your measurements with another multimeter.
- How long is the warranty on the TriStar?
The TriStar carries a 5 year manufacturers warranty.
- Can I use a higher nominal voltage array on a lower nominal voltage battery bank? (e.g. 24V array to charge a 12V battery bank)
No. The nominal voltage of the PV array must match the nominal voltage of the battery bank. This same concept applies to load control as well.
- Can I charge 36V systems?
Yes. The TriStar can be configured to charge a 36V bank using custom settings. We recommend that the user specify the 48V system voltage option using the DIP-switches. Divide the desired setpoint values by four, and program these values using the PC software. When the 48V setting is selected, the TriStar will quadruple the setpoints and regulate at the desired voltages.
- Can I regulate a wind generator or hydro-generator with the TriStar?
Wind, hydro-generators, and other DC charging sources can be regulated using the TriStar in diversion mode. Refer to the TriStar Operation Manual for more details.
- Should I add fuses and/or disconnects to my system?
Fuses, circuit breakers and disconnects should be included in your system. Refer to your local/national codes concerning requirements. The TriStar Operation Manual outlines NEC requirements for installations in the United States.
- Do I have to ground the TriStar chassis?
We recommend grounding the chassis per NEC requirements.
- What size grounding wire should I use in my system?
Minimum Sizes:
TS-45 6mm2 (10 AWG)
TS-60 10mm2 (8 AWG)
- How should I mount the TriStar?
The TriStar should be mounted on a vertical surface out of direct sun with the TriStar heatsink fins oriented vertically. Allow at least 3 inches above the heatsink for airflow.
- Is the TriStar chassis ground the same as electrical negative?
TElectrical negative is isolated from chassis ground.
- How do I size the diversion load bank?
The TriStar Operation Manual (pp 37-42) provides guidelines for diversion load sizing and addresses installation issues as well.
- WDoes the TriStar have communication capabilities?
The TriStar provides one 9-pin RS-232 serial connection. Communication is possible using the TriStarView PC software (free from our website) Alternatively, application-specific software can be written that communicates with the TriStar using the MODBUS industry standard protocol.
- Can I specify my own setpoints?
Yes, you can specify custom setpoints. Using our free TriStarView software, you can configure many of the setpoints and parameters for charge, load, and diversion control.
- Where do I get software to connect to the TriStar?
We supply PC software free of charge. It is available for download on our website. Sorry, Apple Mac is not supported.
- What is the Modbus protocol anyway?
Direct from the FAQ at http://www.modbus.org :
MODBUS® Protocol is a messaging structure developed by Modicon in 1979, used to establish master-slave/client-server communication between intelligent devices. It is a de facto standard, truly open and the most widely used network protocol in the industrial manufacturing environment. It is literally implemented by hundreds of vendors on thousands of different devices in order to transfer discrete/analog I/O and register data between control devices. It's really a lingua franca or common denominator between different manufacturers. One report called it the "de facto standard in multi-vendor integration".
- Can I log system data with the TriStar?
Yes. The PC software will provide logging capability through the serial port. Additionally, a number of commercial dataloggers and PLCs support the Modbus protocol.
- Can I link multiple TriStars together?
TriStars can be linked with their serial ports using RS-232 to RS-485 converters. Each TriStar on the bus will need a unique Modbus ID that can be programmed using PC software.
- Can I connect to the TriStar from a remote location?
Yes. We have tested certain serial to Ethernet converters as well as wireless/cellular modems. The method of communication must not conflict w/ Modbus timing requirements. Refer to the TriStar Applications Guide for different remote communications schemes.
- Where can I find an RS-232 cable?
RS-232 serial cables can be found at just about any computer retail store. In most cases, such as mating the TriStar to a PC, you will require a cable with one male and one female connection. Linking a PC with the TriStar will require a straight-through serial cable (NOT a NULL Modem cable)
- I want to make my own serial cable. What pins do I need (at a minimum)?
The serial port on the TriStar is opto-isolated per UL requirements. For this reason, the TriStar serial port is "port powered", which means it requires a small amount of power from the host (PC or other device). In addition to pins 2,3,& 5, pin 4 and/or 7 should be connected. For more information, refer to the document, "TriStar RS-232 Wiring".
- How many meters can I connect to the TriStar?
We allow up to 2 digital meters to be connected to a single TriStar. Any combination of local and remote meters is acceptable.
Note: due to power limitations on the bus, only one meter can have an illuminated backlight at any given time. A meter will turn off the other meter's backlight if necessary before turning on its own backlight.
- How many TriStars can I connect to my Digital Meter?
We do not currently allow more than one controller per meter.
- Do I need a Remote Temperature Sensor for temperature compensation?
Yes, the optional RTS is required for the temperature compensation feature. If an RTS in not used, the TriStar will not compensate charging setpoints for temperature.
- When I have my array wired to the SunGuard, why
don't I measure a voltage on the battery leads?
The SunGuard requires the battery connection to function properly. Without
a battery attached, the SunGuard's internal circuits cannot power up and allow
current to flow from the Solar input to the battery.
- If my batteries discharge below the SunGuard's
operating voltage at night, will it begin charging again in the morning?
No. The battery must be above the minimum operating voltage to begin charging
the battery. Wire the PV directly to the battery to charge the battery above
the min. operating voltage. The minimum operating voltage of the SunGuard
is approximately 6-7Vdc. - Is it OK to clip off the temperature sensor that protrudes out from the
epoxy?
Removing the temperature sensor will cause the controller to malfunction and
will void the factory warranty. Clipping off the temperature sensor will not
disable temperature compensation. - Which black wire is connected to my battery/solar negative leads?
Both black leads are common so it does not matter which black lead goes to
battery/solar negative. - Can Temperature compensation be defeated?
The temperature compensation feature cannot be disabled on the SunGuard. - Should I ground my SunGuard?
Grounding the SunGuard is not required for correct operation. Grounding the
SunGuard will not damage the unit. Check code/regulations for your application.
SunSaver - When I have my array wired to the SunSaver, why don't I measure a voltage
on the battery terminals?
The SunSaver requires the battery connection to function properly. Without
a battery attached, the SunSaver's internal circuits cannot power up and allow
current to flow from the Solar input to the battery. - What is the purpose of the Temp Sensor that protrudes from the front plate?
The temperature sensor measures ambient temperature. Battery chemistry is
sensitive to temperature and the SunSaver charges batteries as a function
of temperature. If it is warm, the batteries will be charged to a slightly
lower voltage and if cold, to a slightly higher voltage. This is referred
to as temperature compensation. - What is "LVD" and why is it useful?
LVD is an acronym for Low Voltage Disconnect. SunSavers equipped with this
feature will disconnect the DC load if the battery is discharged too low.
This will protect the battery from over-discharge, which can cause damage.
When the battery recharges to a reasonable level, the DC load is reconnected.
- What does "epoxy encapsulated" mean and how does it protect the SunSaver?
At the factory, the SunSaver's circuits are sealed in an epoxy, effectively
sealing the circuits from the environment including moisture, dirt, and other
debris. Sealing the circuits increases reliability and resistance to harsh
environments. The epoxy is thermally conductive to allow heat to dissipate
from the circuits to the surrounding air. - Should I ground my SunSaver?
Grounding the SunSaver is not required for correct operation. Grounding the
SunSaver will not damage the unit. The negative terminals of the controller
are all common. Check code/regulations for your application.
SunLight - When I have my PV array wired to the SunLight, why don't I measure a voltage
on the battery terminals?
The SunLight requires the battery connection to function properly. Without
a battery attached, the SunLight's internal circuits cannot power up and allow
current to flow from the Solar input to the battery. - How does the SunLight keep track of days/time?
The SunLight uses the PV array to determine day/night. Periodically, the SunLight
will check the open circuit voltage(Voc) of the panel. If the Voc is above
or below certain voltage thresholds, the processor determines day/night (after
averaging and time delay). The processor then times the night length. A running
average of night lengths is stored so that a few days of abnormal weather
or other factors does not drastically affect the lighting timing. - Why doesn't my SunLight start charging as soon as I attach my PV array?
The SunLight must be very certain when determining if it is day or night because
the timing function depends on these transitions. When the panel is first
attached, the SunLight will detect that the array is attached and then begin
averaging the open circuit voltage(Voc) of the panel over a period of a few
minutes. This average is then compared to set threshold values to determine
if it is in fact daytime. This process can take up to 10-15minutes. - Should I ground my SunLight?
Grounding the SunLight is not required for correct operation. Grounding the
SunLight will not damage the unit. The negative terminals of the controller
are all common. Check code/regulations for your application. - What are the details on the Test button?
The test button allows the user to turn on the load for 5 min to verify system
wiring. After the button is pressed, the LVD LED will blink to indicate the
timer setting switch position for verification. The test feature will limit
the 5min load-on to 3 times when in LVD. - Can I use the SunLight to run loads during the daytime instead of nighttime?
Using normally-closed relays, it is possible to inverse the load timing
function including the Dusk-to-Dawn setting. This will allow the loads to
run during the day and switch off at night. Refer to the, "SunLight
Load Relay document". - Can the light timing setpoints be changed?
The setpoints are programmed in the SunLight's microprocessor and there is
no provision to update them at this time.
ProStar(15 and 30) - What is the purpose of the "Sense" connections on the ProStar?
When the battery bank is located far from the controller, a significant voltage
drop can occur over the long battery cables due to the resistance in the cables.
The Sense connection allows the user to run an extra pair of small gauge wires
that can measure the battery voltage without the voltage drop (they carry
very little current) - Can a meter from another ProStar be fitted on any other ProStar?
Yes. The meter boards are interchangeable between metered ProStars of the
same version. Older version ProStars may require a calibration procedure,
whereas the newer version meters are "plug and play". - How should I mount the ProStar? How much space for cooling should I allow?
The ProStar should be mounted on a vertical surface with at least 6in(15cm)
of space above and below the unit for airflow. The back plane should not be
easily combustible because of its close proximity to the heatsink, which may
get hot under certain operating conditions. - How do I distinguish between the newer ProStar and the older version?
Refer to the document, "Distinguishing
ProStar Versions" - How does the ProStar "know" when to equalize my batteries?
Equalization will be triggered if 25 calendar days have passed, or if the
battery discharges to a certain voltage on the previous day. The ProStar does
not equalize in the Gel battery setting and equalizes to different levels
and lengths of time depending on the battery type. - Should I ground my ProStar?
Grounding the ProStar is not required for correct operation. Grounding the
ProStar will not damage the unit. The negative terminals of the controller
are all common. Check code/regulations for your application. - How does the Self-Test feature work? (meter versions only)
When the self-test begins, the ProStar's processor performs a check of the
internal circuits and takes readings to discover any failures. If any errors
are found, error codes are listed along with other pertinent information on
the LCD display for reference. This enables the user to more easily troubleshoot
the ProStar. - Why would I need the remote temperature probe?
The remote temperature probe should be used whenever the battery and controller
are not in the same ambient conditions. Since battery charging is a function
of temperature, the controller should be in similar temperatures as the batteries
to regulate accurately. The temperature probe allows the controller to sense
the temperature at the battery bank; else it just defaults to its on-board
temp sensor. - Under what conditions does the ProStar enter the float stage of charging?
After the ProStar has been in Regulation for a while, it will drop into a
float charge. The Float stage lowers the battery voltage and minimizes gassing
of the batteries. In PWM Regulation, if the controller has been limiting the
input current to 30% or less for one hour, the ProStar will drop into the
float stage. If the battery voltage had dropped below 11.9V(23.8V) before
recharging, it will wait 2 hours before transitioning to the Float stage.
- What is "conformal coating"?
Conformal coating is a clear protective sealant that is applied to the ProStar's
circuit boards to protect against moisture, dirt, and debris. This coating
increases resistance to harsh and humid environments and marine applications.
- Does the ProStar have internal fuses? Do I need external fuses?
The ProStar does not have any internal fuses. Electronic protections are used
to prevent damage due to short-circuits and other faults. The ProStar will
auto-reconnect once the faults are cleared. Morningstar recommends the use
of external fuses and disconnects in your system. Use protections as local/national
code and regulations require.
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