Anyone Here Have a TriStar 45 MPPT charge controller installed???
CBear42
Solar Expert Posts: 28 ✭
I have a situation where the "installer" didn't install (he lost - or whatever) the button to reset the charge controller. I am trying to clear a HVD error...and can't.
I have tried cutting off the breaker to the charge controller - the dummy lights are still lit. (Battery-powered? Magic?) I have cut ALL power to the house - and they're still lit. I have tried pushing the "button" with the front panel off - no luck. The lights remain lit and flashing.
I would like to reset/restart the controller - but it seems to be sitting outside of my control! Everytime I try to charge my low batteries for the last two days - it goes to this error.
Additionally, I would like to reset the DIP switches on the controller to reflect that the system is 24 volt. (My fraudulent, lying installer didn't bother to set any custom switches...). But it immediately goes to a G-Y-R light sequencing...even if the power is "off". Resetting at the breaker has no effect.
Two questions:
1. Are the batteries charging with the HVD error lights flashing?
2. How can I clear the error? Reset the DIP switches?
BTW, the appalling lack of user documentation for these products is nothing short of criminal. They were obviously written by engineers for installers who leave. Period. There is nothing in the docs or manuals about key concepts that might be related to troubleshooting problems. There are references to self-diagnostics - but no clue as to what they are. References to "restarting" the controller -but no clue as to how. References to "faults and errors" - but no trouble tree to help diagnose the problem. Arrgh! This is Morningstar's docs. Outbacks are even worse. An installation manual and a programming manual. No ongoing maintenance/user manual at all.
Thanks in advance (sorry for the rant)
CBear
I have tried cutting off the breaker to the charge controller - the dummy lights are still lit. (Battery-powered? Magic?) I have cut ALL power to the house - and they're still lit. I have tried pushing the "button" with the front panel off - no luck. The lights remain lit and flashing.
I would like to reset/restart the controller - but it seems to be sitting outside of my control! Everytime I try to charge my low batteries for the last two days - it goes to this error.
Additionally, I would like to reset the DIP switches on the controller to reflect that the system is 24 volt. (My fraudulent, lying installer didn't bother to set any custom switches...). But it immediately goes to a G-Y-R light sequencing...even if the power is "off". Resetting at the breaker has no effect.
Two questions:
1. Are the batteries charging with the HVD error lights flashing?
2. How can I clear the error? Reset the DIP switches?
BTW, the appalling lack of user documentation for these products is nothing short of criminal. They were obviously written by engineers for installers who leave. Period. There is nothing in the docs or manuals about key concepts that might be related to troubleshooting problems. There are references to self-diagnostics - but no clue as to what they are. References to "restarting" the controller -but no clue as to how. References to "faults and errors" - but no trouble tree to help diagnose the problem. Arrgh! This is Morningstar's docs. Outbacks are even worse. An installation manual and a programming manual. No ongoing maintenance/user manual at all.
Thanks in advance (sorry for the rant)
CBear
Comments
I don't have one, but if it's like 99% of the others, There is no button, never was. Stick a ballpoint pen or a tooth pick in the hole and push the reset switch on the pcb board. If it's auto ranging it probably didn't need the switches set.
http://www.morningstarcorp.com/en/tristar%20mppt will get you to the online docs.
Item # 17 is the button.
Hmmm... On page 40 of the instructions, it indicates that you have entered the equalizing stage... It also says that the button will reset the battery service indication if this has been activated in custom settings. Not sure if this mean you have to program this function via computer... Also, if it is at factory settings, it is using battery voltage to sense what size bank you have... Do you have a breaker between the controller and battery you can turn off? As well, if you have factory settings, then it may not be right for your kind of batteries, as shown on page 19... Also, it talks about the auto-equalize function on page 20... That's as far as I am with mine, as the batteries need to be picked up this week...
Hey guys,
Thanks for the quick replies. But, I have the read the docs. The problem is pushing this button has absolutely NO EFFECT on the error code or the lights themselves. Cutting off the breakers to everything in the house - also has no effect on the charge controller - apparently.
I agree, paulskirocks (nice name) - the factory settings probably aren't correct. BUT, the charge controller isn't letting me alter them via the DIP switches. As soon as I try to alter them - it starts the G-Y-R sequencing that indicates I tried to change the DIP switch settings while power was connected. Supposedly, using the reset button would allow you to still reset the DIP switches. BUT, my button has no apparent effect on the operation of the controller. I have tried at least 50 times to reset the switches with varying configurations of breakers on/off, etc. No luck with any of those.
I have a breaker to the inverter, a breaker between the PV panels and the charge controller, a breaker between the inverter and the house - and none of them have any effect.
Thanks,
CBear
Ah, but you have no disconnect between the controller and battery? Also, did you press and hold the rest button for five seconds, according to manual, to cancel equalize?
Yes, AFAIK, there is no disconnect between the controller and the batteries themselves.
Also, there is no automatic equalize set up - via the DIP switches - which is one thing I was wanting to do.
So, yes, the button has been held - although according to the Morningstar software logs - these batteries have NEVER been in an equalization mode.
The button - has NO effect.
Thanks,
CBear
Well, I would disconnect the battery before going any further...
Also, just to clarify - the LED buttons do not indicate that I am in Equalization mode.
They are sequencing G-R rapidly. According to docs this = High voltage disconnect G / R sequencing
Equalization mode is = Equalize request start G+Y+R / G+Y+R / G / G
Thanks,
CBear
This little tidbit from page 44: "Settings (DIP) Switch Changed (R / Y / G sequencing)
If a settings switch is changed while there is power to the controller, the LED’s will begin sequencing
and the solar input will disconnect. The controller must be restarted to clear the fault
and begin operation with the new settings."
So, now the solar has been disconnected, but the only way to restart (not reset) the controller would be to disconnect battery power, change the dip switches, then reconnect battery...
Don't own this charge controller, but they seem well respected in the field. The Charge controllers I have owned, I made changes to the dip switches when there was no power to the charge controller. I suspect the Switces set for 12 volt and you want to change to 24 volt. It's 'seeing' the higher voltage and shutting down.
I suspect that the installation instructions state to set the paramiters/dip switches for battery, voltage, type, charging voltages, monthy equalizing,.. before being attached to the batteries and to hook up to batteries, and bringing the CC up, before flipping the switch for your array.
So first I would attach the CC to the other side of your battery inverter breaker, then you should be able to shut the CC down with the same breaker.
- Assorted other systems, pieces and to many panels in the closet to not do more projects.
Well, no matter what, as per page 27: "Circuit breakers or fuses must be installed in both the battery and solar circuits." Not only will you be safer, you can then disconnect the battery and restart the whole thing...
Thanks everyone - I appreciate all the time you've taken and the responses you've made.
This gives me (at least) a place to start. I also have a call into Morningstar Corp and hopefully, they can point me further along the way.
Happy New Year all and Happy Solar-ing!
CBear
This charge controller _must_ have the batteries disconnected in order to be shut down. It will not run on PV power, it will only be powered on when the batteries are connected. If you have not disconnected the batteries when you are trying to change the DIP switches you need to do so. Should not be any need to wait for Morningstar to get back to you.
As for the lack of documentation, this info is all from the manual that I received when purchasing my charge controller and it seemed they had good docs available online as well. Perhaps your unscrupulous installer simply tossed the nice "manual" that is more like a book.
I have 2 of the Morningstar TS-60 which is a PWM version, but operates very much the same. I suggest you CAREFULLY disconnect the voltage sense wires. (That may be giving it power when the breakers are off, haven't tried it on mine) I always connect the solar connector on the charge controller to the correct size breaker (Load side) and the line side of the breaker to the solar panel or string(s). The battery connection goes to the load side of the breaker and the line side goes to the positive bus. I use Midnite breakers and bus bars from NAWS. Very handy things to have around. Both breakers need to be off in order to power down the controller, and don't forget to disconnect the voltage sense wires very carefully as they will be hot. I would disconnect the sense wires at the battery first.
Skip
I've have both the "standard" PWM TS-60 and now using the TS-MPPT-60. They are basically identical to the 45 models In all cases, the controller must be de-powered BEFORE the dip switches are changed! It's in the manual. There MUST be a breaker or fuse between the controller and batteries! Otherwise, a short in the controller could draw full battery power and cause a fire! It's VERY easy to restart / reset these controllers. First, cut the power from the panels (to be safe), THEN cut the power from the batteries! It then receives no power, so will be powered down! Then reconnect the battery power to the controller (switch the breaker back on, or reinstall the inline fuse etc), the three lights will sequence, then settle on the battery voltage state. Then reconnect the solar panels. There is NO WAY to shut down or reset the controller without cutting battery power!
Of course the lights will continue in alarm until the controller has been powered down and restarted.
No, these wires only provide battery voltage sensing signal, they do not provide operating power to the controller. His problem, apparently, is that he has no breaker or fuse between the batteries and the controller. Scary! And no switch, so the controller is constantly receiving power from the batteries therefore cannot be shut down. And if it can't be shut down, it can't be restarted and the alarm state can't be reset.
I have the MPPT 60, big brother of yours. You have to disconnect it from the batteries to reset. Your installer owes you another breaker. Also get a serial-USB translator cable, and you can program and clear errors from your computer.
|| Midnight Classic 200 | 10, Evergreen 200w in a 160VOC array ||
|| VEC1093 12V Charger | Maha C401 aa/aaa Charger | SureSine | Sunsaver MPPT 15A
solar: http://tinyurl.com/LMR-Solar
gen: http://tinyurl.com/LMR-Lister ,
https://www.manualslib.com/manual/1267528/Morningstar-Tristar-Ts-60.html?page=22#manual
4.4.1 Standard Equalization Programs
-Bill
It must have a breaker on the source/generator and another breaker on the batteries.
The DIP's must be set for your battery voltage and for there charging regime. I always set equalisation for manual as it would conflict with my other Morninstar Tristars. It is also possible with a Laptop to get access to the internal settings for minor adjustments to the DIP's settings. A led display Screen is also helpful as you can walk gently through what it is doing and switch on /off the Equalization.
As you can see in the photo its along side a Midnite200, but i much prefer the Tristar 45 MPPT.
My other Tristars, set for diversion loads, are also bulletproof and even continue doing there job when overloaded and then another steps in, the first show Error but carry's on.
Yes, after 12 years using Morningstar Tristars i can not fault them.
Everything is possible, just give me Time.
The OzInverter man. Normandy France.
3off Hugh P's 3.7m dia wind turbines, (12 years running). ... 5kW PV on 3 Trackers, (8 years) .... 14kW PV AC coupled using Used/second hand GTI's, on my OzInverter created Grid, and back charging with the AC Coupling and OzInverter to my 48v 1300ah batteries.
Bill "carry on" B.