Morningstar REAKSTAR GenStar GS-MPPT-60M-200V Installation, Operation And Maintenance Manual
Solar battery charger & load controller with maximum power point tracking technology
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Summary of Contents for Morningstar REAKSTAR GenStar GS-MPPT-60M-200V
- Page 1 GenS MPPT™ Solar DC System Controller Installation, Operation and Maintenance Manu al Solar Battery Charger & Load Controller With TrakStar Maximum Power Point Tracking Technology MODELS GS-MPPT-60M-200V GS-MPPT-80M-200V GS-MPPT-100M-200V MAXIMUM POWER POINT TRACKING...
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Page 2: Table Of Contents
3.5.1 Methodology....................... 2 5 100A Current 3.5.2 Commissioning Menu..................25 Rated Load Current Array voltage should never exceed this limit 3.5.3 Stand-alone commissioning Settings..............25 150% of Nominal Maximum Output Power Maximum includes battery current plus any load current (Cont.) MORNINGSTAR CORPORATION MORNINGSTAR CORPORATION... - Page 3 5.2 GenStar MPPT Charging..................... 44 6.0 Networking and Communications...........63 5.2.1 Charging Algorithms....................44 6.1 Introduction..................... 63 5.2.2 Charging Profiles......................45 6.2 Morningstar MS-CAN (MS-CAN functionality is not available with 5.2.3 Bulk Charging Stage....................47 this release.)....................63 5.2.4 Absorption Stage...................... 4 7 6.3 Serial RS-232..........................64 5.2.5 Float Stage.......................47...
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Page 4: Important Safety Instructions
• Install the GenStar MPPT in a location that prevents casual contact. The GenStar MPPT heatsink can become very hot during operation. • Use insulated tools when working with batteries. • Avoid wearing jewelry during installation. GenStar MPPT MORNINGSTAR CORPORATION... - Page 5 • The battery bank must be comprised of batteries of same type, make, and age. • Have someone nearby to assist in case of an accident. • Certified for use in negative ground systems, or positive ground with floating array •...
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Page 6: General Information
2.3 Features - Exterior 2.0 GENERAL INFORMATION GenStar MPPT exterior and meter features are shown in Figures 2-1 and 2-2 below. A brief 2.1 Overview description of each feature follows the figures. Thank you for choosing the GenStar MPPT charge controller with TrakStar MPPT Technology. - Page 7 5 - State-of-charge LEDs 14 15 16 18 19 General battery state-of-charge indicators See future Morningstar ReadyShunt updates for precise battery voltage measurements See Morningstar ReadyBMS accessory for precise battery management system voltage measurements Figure 2-3. GenStar MPPT Interior Features...
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Page 8: Optional Accessories
The ReadyRelay is an expansion block that adds AC and DC-rated relay dry contact hardware 8 - Positive Load Terminal Lug functionality and firmware control and logic to the Morningstar GenStar MPPT charge controller. Positive connection point for loads ReadyShunt (RB-Shunt-1) -
Page 9: Installation
• The maximum wire size is 1/0 AWG / 53 mm (multi-strand). Torque tightly up to 100 in-lb. 3.0 INSTALLATION AND COMMISSIONING • Stranded wires to be connected to the GenStar MPPT terminals should be prepared first with, e.g., clamped copper heads, etc. to avoid the possibility of one conductor coming free. 3.1 General Installation Notes •... - Page 10 B) Use the two remaining screws to secure the (2) unit lower frame holes flush with the wall. STEP 3(D) Insert and 3.3 Required Overcurrent Protection Devices (OCPD) and Disconnect Switches pull down NOTE: Definition Overcurrent protection devices are defined as breakers or fuses. Strictly, a disconnect switch is device that only breaks a circuit - but provides no overcurrent protection.
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Page 11: Wiring
Battery breakers or fuses must be sized with a minimum of 125% of the continuous output current If 156% of PV array Isc is greater than the maximum PV input breaker or fuse current rating, the PV array breaker or fuse should be located at the output of the PV array combiner. rating of the solar controller. -
Page 12: Battery Sense Wires
Accepted practice for system design requires that DC conductors are sufficiently sized to limit Battery Voltage Sense is a high impedance connection that enables the GenStar MPPT to measure voltage drop losses to 2% or less. The table in Appendix C provides wire sizing information and the battery terminal voltage precisely with small gauge wires that have no voltage drop. -
Page 13: Remote Temperature Sensor With Ferrite Choke
3.4.2 Remote Temperature Sensor With Ferrite Choke - refer to Figure 3-3 above CAUTION: Equipment Damage To enable temperature compensation settings (mV/ °C) which are required for Lead-acid batteries, an RTS must be used. Otherwise, charging will be based on a temperature of 25°C. Use of an RTS is strongley recommended. -
Page 14: Battery Connections
GenStar’s maximum load current rating, the device (-) post while installing the system or while system wires are exposed. should be wired directly to the battery or battery bank. If load control is required, contact Morningstar Technical Support for assistance. -
Page 15: Readyblock Installation
STEP 1: OPEN any load disconnects or breakers, and turn OFF any loads. STEP 2: Connect positive and negative wires to the load, and to any load bus bars or load panel terminals. STEP 3: Install a correctly sized load/output breaker or fused disconnect switch in the OPEN position located near the load output terminals of the controller. -
Page 16: Final Connnections
3.4.8 Final Connections 3.4.10 To Power-down WARNING: Equipment Damage WARNING: Equipment Damage Connecting the battery cables with reverse polarity will permanently damage the ONLY disconnect the battery from the GenStar MPPT AFTER the solar input has been GenStar. disconnected. Damage to the controller may result if the battery is removed while the GenStar MPPT is charging. - Page 17 The commissioning flowchart in Figure 3-6 below illustrates the selectable options required to prepare the GenStar MPPT for operation or further programming. RTS START-UP and RUN-TIME BEHAVIOR TABLES Initial Set UTC- RTS REQUIRED - NO Power-up RTS REQUIRED - YES Time START-UP BEHAVIOR (default must be changed in...
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Page 18: Configuration
DC load control, Ready Blocks, date Morningstar LiveView web pages. See the main LiveView web page for locations and screens. The and time, network configuration sections describe all settings details in terms of LiveView screens, and many settings... -
Page 19: Using Liveview
• DC Load: View all low voltage disconnect (LVD) and reconnect thresholds, LVD and SOC disconnect timers, SOC disconnect and reconnect percentages, load current compensation LiveView is an interface that serves Morningstar application web pages directly from the value GenStar MPPT. The web pages closely coincide with the GenStar MPPT meter layout and functions. -
Page 20: Sd Card And Logged Data Storage
2) Time server - if the GenStar MPPT is connected to the Internet, it has the ability to periodically Format SD Card; Delete Log Data; Delete Settings File; Delete Firmware File. update time and date from a time server(s). Go to Installer Setup\Network to specify up to three (3) The SD Card menu offers the following information and functions: time server addresses. -
Page 21: Charger (Installer Setup)
For more standard settings infomation, and further custom settings adjustment, expand the Installer 1) Voltage Only - only voltage-related values are adjustable Setup bar at the bottom of the section. 2) State-of-charge (SOC) ONLY - availability depends on system configuration 3) State-of-charge (SOC) and Voltage - both SOC and voltage values are adjustable. -
Page 22: Schedules
The ReadyRelay is an expansion block that adds AC and DC-rated relay dry contact hardware Schedules menu. functionality and firmware control and logic to the Morningstar GenStar MPPT charge controller. NOTE: Proper generator/auxiliary equipment relay wiring is required - see ReadyRelay ReadyShunt (RB-Shunt-1) manual for terminal connections diagram. - Page 23 2) MANUAL - External Source starting can be triggered manually via Command or Soft-key. EXTERNAL SOURCE CONTROLS TIMING SEQUENCE EXAMPLE Once a ReadyRelay has been designated as a Command/Schedule signal, use Commands or Soft- (Intervals are met when elapsed time equals required time) key - see Section 4.2.7 #5 and 4.2.9 - to start or stop an external source manually.
- Page 24 Start Charging (Charging 1,2 and 3) can be designated using: ESC Schedules and Conditions (Installer Setup\ESC\ Modes\Custom) • On Schedule timing. Conditions can be customized. • Low Battery / complete Bulk - voltage and time. Conditions can be customized and scheduled. •...
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Page 25: Local Meter Display And Button
INSTALLER SETUP De ne Relay Signal Select Relay Block The GenStar MPPT utilizes Morningstar’s TrakStar Maximum Power Point Tracking technology to to con gure extract maximum power from the solar module(s). The tracking algorithm is fully automatic and does Select relay A or B not require user adjustment. -
Page 26: Genstar Mppt Charging
5.2.2 Charging Profiles GenStar MPPT offers eight (8) preset battery charging profiles, as seen in Tables 5-1 below. These standard charging settings are suitable for lead-acid batteries ranging from sealed (gel, AGM, 12 Volt Module 12 Volt Module maintenance-free) to Flooded and Lithium cells. All voltage settings listed are for nominal 12 Volt Current vs. -
Page 27: Bulk Charging Stage
Load HVD Load HVR 5.2.3 Bulk Charging Stage GenStar MPPT Load Battery Type-Preset Volts Volts HVD-HVR Preset During Bulk charging, the battery is not at 100% state of charge and battery voltage has not yet Charging Settings 1 - Lead-acid Disabled Disabled charged to the Absorption voltage set-point. -
Page 28: Charging Variables
Certain batteries benefit from a periodic boost charge to stir the electrolyte, level the cell voltages, Many VRLA batteries, including AGM and gel, have charging requirements up to 14.4V (12V battery). and complete the chemical reactions. Equalization (EQ) charging raises the battery voltage above Depending on the battery manufacturer’s recommendation, the “boost”... - Page 29 Float Cancel Voltage Float Exit Time-out Voltage Threshold Bulk Absorption Bulk Absorption Absorption Float Bulk Voltage Float cancelled this charge cycle Float Exit V L-A = 12.6V Lith. = 13.3V 12.0 V Float Cancel Voltage 60 mins. below Float Exit Voltage time (hrs) 1:00 2:00...
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Page 30: Load Control Information
GenStar’s maximum voltage or current limits, the device should be wired Setup\Installer Setup, and enter Installer Password 141. Then navigate to Commands\Factory Reset directly to the battery or battery bank. If load control is required, contact Morningstar Tech Support and choose that option. -
Page 31: Battery State-Of-Charge (Soc) Led Indications
Condition Green LED Yellow LED Uncalibrated Network Connection OK The controller was not factory calibrated. Contact your Authorized Morningstar Dealer for service. Network Activity Blinking Error READYBLOCK ALARMS 5.7 Alarms and Faults A BMS, Shunt or Relay Block can trigger the following alarms on the host which will trigger a... -
Page 32: Liveview Menus
GenStar MPPT regulation voltage. Recovery occurs at HVD re-connect threshold, and the fault will clear automatically. LiveView is Morningstar Web Pages served directly from the GenStar MPPT. The web pages closely coincide with the GenStar MPPT meter layout and functions. Many LiveView pages are organized into cards, which are rectangular areas that group commands, settings, and other information. -
Page 33: Commands
5.9 Commands 5.9.5 External Source Control (ESC) Commands Commands can be accessed in the main LiveView dashboard, or in the primary meter screen. Control external source signal with commands: Commands are used to control the functions in Sections 5.9.1 - 5.9.6 below. Also see LiveView •... -
Page 34: Event Logging
Firmware can also be updated via RJ-45 (Ethernet) connection using LiveView. • Charge Ah GenStar MPPT firmware must first be downloaded from the Morningstar Website: morningstarcorp. • Load 0 Ah com. The firmware file will download to your computer as ZIP folder and will need to be extracted for use. -
Page 35: Networking And Communications
• Display net system data for multiple GenStar MPPT systems • Share battery termperature information across multiple GenStar MPPT controllers • Synchronize charging stages across multiple GenStar MPPT controllers • Aggregate data and centrally control Morningstar load devices like SureSine inverters Operation GenStar MPPT... -
Page 36: Serial Rs-232
EIA-485 network if the nominal system voltage is greater than 12 volts. Default Serial Port Settings: • 9600 Baud rate For more information on EIA-485 networking, refer to the, “Morningstar Communications Document”, on our website at: • 8 data bits •... -
Page 37: Ethernet
The controller’s MAC Address is located on the serial label on the side of the controller. This section provides a summary of each feature. For detailed information about Ethernet Two (2) LEDs on the Ethernet jack indicate link and activity status. connectivity and networking, refer to the, “Morningstar Communications Document”, on our website at: Condition... - Page 38 7.0 TROUBLESHOOTING High Solar Voltage Disconnect WARNING: RISK OF ELECTRICAL SHOCK. Status LED: None. Battery Status LEDs: R-Y-G. If the solar input open-circuit voltage (Voc) exceeds NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROM DC INPUT, the 185 Volt maximum rating, the array will remain disconnected until the Voc falls to 175V AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE.
- Page 39 (E) multi-meter available (for field troubleshooting) If the dealer is contacted, and is not able to assist with warranty claim, contact Morningstar Tech support at support@morningstarcorp.com. Provide proof of date and place of purchase, and all details listed in preceding paragraph.
- Page 40 Maximum Battery Current 60 Amps 80 Amps 100 Amps AND FITNESS FOR A PARTICULAR PURPOSE. No Morningstar distributor, agent or employee is Maximum Input Voltage ALL: 200 Volts authorized to make any modification or extension to this warranty. Maximum Input Current...
- Page 41 APPENDIX A - Wire Sizing Information GENSTAR MPPT - all models Wire sizing requirements are based on the ampacity (current carrying capacity) of conductors. The Communication-Interfaces: NEC includes Ampacity Tables which are used to determine the ampacity for a given wire size as SD Card indicated in Section 310.15.
- Page 42 Minimum Battery Wire Sizing 75ºC rated copper 2% Voltage Drop Chart for 75°C or 90ºC Stranded Copper Wire Wire Size in a raceway, cable, Metric Wire Size in free air Maximum 1-way distance (feet), 12 Volt system - multiply values by (2) for 24 Volt, or earth MODEL Wire Size...
- Page 43 Table A-5. Maximum 1-way wire distance for 12 Volt systems, stranded copper, 2% voltage drop GenStar MPPT and Meterbus Morningstar Corporation MODBUS and MODBUS TCP/IP are trademarks of Modbus IDA. ©2022 Morningstar Corporation. All rights reserved. MS-003633 v1 Certifications Appendices...
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