Risk of destruction to TS-MPPT-60 with use of MSView:
I am creating this topic with the understanding that the details contained herein have as yet not been brought to light on this forum and to inform and bring to attention to users of the highly probable risk of destruction to this model charge controller.Summary:
I assisted in the installation of a new Morningstar TriStar TS-MPPT-60 charge controller late last week as part of a full upgrade of a renewable energy system. (one of the three Amigos) . During the process of commissioning I was able to effectively destroy the unit while performing an action from a connected laptop running the Morningstar application called MSView.

Details:
A new TS-MPPT-60 was installed on 23 April 2015 as part of a complete revamp of an existing system. The charge controller was connected and powered up on this date and appeared to be fully functional.

On Monday 27 April 2015 the commissioning of the system was closer to completion, with the complete PV array of 2250 Watts of PV panels being brought online. The morning was proceeding well and the TS60 was putting in good charge into the new 400Ahr 25.6Volt LiFeYPO4 battery bank with clear skies and good sun giving photons being absorbed by the PV array.

The time was around 10h30 and we noticed the TS60 was flitting between the two modes of ‘MPPT’ and ‘ABSORB’, and we were not sure to the exact reason for this, as the expectation was that it would stay in MPPT mode until it reaches the absorb voltage and then would lock itself into the ‘ABSORB’ mode for the specified absorb period, which we had set to 45 minutes.

At around 10h45 we were expecting the TS60 to complete the ‘ABSORB’ cycle of 45 minutes to then return to ‘FLOAT’ mode. We gave it some minutes extra, but it continued to flit between the two modes mentioned above.

What we also noted at this same time was that the LCD on the TS60 was at times, showing for a very brief period, a fault indication, before resuming where is was. There was no faults listed in the diagnostics log and so we weren’t sure what was the cause of this.

What we did next was to turn OFF the PV isolator switch, a Blue Sea 5510e dual circuit switch.
Then we connected a laptop to the TS60 via RS-232 serial cable, with the laptop being powered from its internal battery pack. We brought up the Morningstar software called MSView to read in the settings to check all was in order.

We read in the TS60 configuration and looked over it in the MSView software. We then made a small change to the settings, changing the ‘absorb’ period from 45 minutes to 48 minutes. Next we wrote the configuration back to the TS60. Then we wanted to reset the TS60 so it would take in the new setting, which we could do easily by a special function in the MSView software. This function, is ‘Control Reset’ is seen under menu item ‘Devices | Properties’ in a list of other actions.

With the PV array isolation switch turned OFF, so no input voltage present to the TS60 we selected ‘Control Reset’ and on the click of the mouse button we heard a definite ‘pop’. Small, but a ‘pop’

There was no smell and the TS60 continued to appear to function as normal, and we thought maybe the ‘pop’ was just metal expanding in the sun of the workshop or some other sound we hear in the Australian bush. We thought about it for a few minutes.

We concluded everything appeared normal and we decided to bring back on the PV array isolation switch and with that, a more definite ‘bang, crack, pppffft’ was heard with a faint but distinct smell of something electronic, not the sweet bush fragrance.

Two of us ran to the bush while one brave sole thankfully had the good mental state to turn OFF the PV array isolator, before quickly joining us in getting fresh air also.

After the event:
I was on the phone right away to our supplier and the unit was shipped back using overnight express on that same day. It arrived at our supplier the following day and together with a report I wrote, similar, though slightly longer with more details than above, yes, you can believe that, for the Mornigstar folks in the States.

I wanted that they were informed about every detail of our misadventure as I have never enjoyed the bangs, cracks and other loud noises emanating from supposedly reliable equipment, I nearly soiled my pants.

Advice from Morningstar:
Today, we received a phone call from our supplier in NSW who I must say has been absolutely professional and attentive to us in every respect, though he has asked not to be named, wishes I will respect.

The reply from the Morningstar company back in the States, to which they advised to words of the effect, ‘Yes, we have been made aware of this and is a known issue with the TriStar TS-MPPT-60 charge controller, please avoid any use of the “Control Reset” function within our MSView software’.

Our supplier has, on this advice, express freighted to us a new replacement unit he has in stock, for which we are thankful. I was imagining a period of at least a few weeks before something might be resolved, and had already re-instated a Plasmatronics PL40 to tie over the period on a re-arranged PV array.

Notes:
My suspicion is that it appears to be a section of badly coded and untested firmware within the unit.
We also found in our online searches that another user of a TS60 has had the very same happen, albeit with the PV array still online top the TS60. His TS60 was replaced by Moringstar also. This same person posted on yet another forum and attracted yet another user who, also with a TS60, had the exact same issue, again, with the PV array online. In fact this second person was unlucky to have this happen two times to him.

Gordon, I hope it will be ok for me to reference the thread on that other forum I mentioned above so people can read that if they wish?
http://forum.solar-electric.com/forum/solar-electric-power-wind-power-balance-of-system/off-grid-solar-battery-systems/13160-black-smoke-from-morningstar-mppt-60-controller

Reply #17 details the second unlucky user I mentioned above.
Reply #24 makes it clear what this person did to destroy the unit.
Reply #25 details the unit was replaced by Moringstar.

Please notice the date of these posts, March 2012, just over three years ago.
What have Morningstar done in this time to rectify the issue, nothing?

We made a short video of the TS60 just prior the first ‘pop’ when it was displaying the ‘FAULT’ on the LCD and the red LED was lit. https://youtu.be/wzTq3vdE0BE

Please excuse any grammatical errors, it’s been a long few days 
____
Paul