Morningstar GenStar GS-MPPT-60 Installation, Operation And Maintenance Manual
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Morningstar GenStar GS-MPPT-60 Installation, Operation And Maintenance Manual

Morningstar GenStar GS-MPPT-60 Installation, Operation And Maintenance Manual

Solar battery charger & load controller with trakstar maximum power point tracking technology
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Solar DC System Controller
Installation, Operation and Maintenance Manu al
Solar Battery Charger & Load Controller
With
TrakStar
Maximum Power Point Tracking Technology
TM
MODELS
GS-MPPT-60M-200V
GS-MPPT-80M-200V
GS-MPPT-100M-200V
MAXIMUM POWER POINT TRACKING

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Summary of Contents for Morningstar GenStar GS-MPPT-60

  • Page 1 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...

  • Page 2: Specification Summary

    2000-4000- 1200-2400- Recommended PV 4800W 6400W 8000W Input Power Maximum Charge 100A Current Rated Load Current Array voltage should never exceed this limit 150% of Nominal Maximum Output Power Charge Current - Load Current = Net Battery Current MORNINGSTAR CORPORATION...

  • Page 3: Table Of Contents

    3.4.4 BATTERY CONNECTIONS 3.4.5 SOLAR CONNECTIONS 3.4.6 LOAD CONNECTIONS 3.4.7 READYBLOCK INSTALLATION 3.4.8 Final Connections 3.4.9 Power-Up and Verify System Operation 3.4.10 To Power-down 3.5 Commissioning / Initial Configuration 4.0 CONFIGURATION 4.1 Adjusting Settings 4.1.1 Using the Meter Display MORNINGSTAR CORPORATION...
  • Page 4 4.1.2 Using Morningstar Mobile 4.1.3 Using the LiveView UI 4.1.4 LiveView Screen 4.1.5 Settings Screen 4.2 Setup and Installer Setup 4.2.1 Date and Time 4.2.2 Network Settings 4.2.3 SD Card and Logger 4.2.4 Load Control 4.2.5 Charger 4.2.6 Schedules 4.2.7 ReadyBlocks and ReadyShunt SOC Measurements 4.2.8 External Source Control (ESC)
  • Page 5 5.8.6 ReadyRelay Commands 5.9 History 5.10 Firmware Updates 5.11 Inspection and Maintenance 6.0 NETWORKING AND COMMUNICATIONS 6.1 Introduction 6.2 Morningstar MS-CAN 6.3 Serial RS-232 6.4 Modbus and ModbusIP via EIA-485 6.5 Ethernet 6.6 Simple Network Management Protocol (SNMP) 6.7 Network Information 6.8 Accessing LiveView Web Pages...

  • Page 6: Important Safety Instructions

    1.0 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. This manual contains important safety, installation, operating and maintenance instructions for the GS-MPPT-60M-200V, GS-MPPT-80M-200V, GS-MPPT-100M-200V. For safety purposes, these instructions must be followed during installation, operation and maintenance of the GenStar MPPT solar controller. The following symbols are used throughout this manual to indicate potentially dangerous conditions or mark important safety instructions: WARNING: Indicates a potentially dangerous condition.
  • Page 7 WARNING: Shock Hazard This unit is not provided with a GFDI device. This charge controller must be used with an external GFDI device as required by the Article 690 of the National Electrical Code for the installation location. • Mount the GenStar MPPT indoors. Prevent exposure to the elements and do not allow water to enter the controller.
  • Page 8 • Determine if battery is inadvertently grounded. If so, remove the source of contact with ground. Con- tact with any part of a grounded battery can result in electrical shock. The likelihood of such a shock can be reduced if battery grounds are removed during installation and maint enance (applicable to equip- ment and remote battery supplies not having a grounded supply circuit).

  • Page 9: General Information

    2.0 GENERAL INFORMATION 2.1 Overview Thank you for choosing the GenStar MPPT charge controller with TrakStar MPPT Technology. The GenStar MPPT is a maximum power point tracking solar battery charger. The controller features a smart tracking algorithm that finds and maintains operation at the power source's peak power point, maximizing energy harvest.

  • Page 10: Features - Exterior

    2.3 Features - Exterior GenStar MPPT exterior and meter features are shown in Figures 2-1 and 2-2 below. A brief description of each feature follows the figures. Figure 2-1. GenStar MPPT Exterior Features EXTERIOR FEATURES: 1 - Meter Display Screen 7 - ReadyBlock Cover Screw LCD read-out for setting and programming navigation 8 - ReadyBlock Tabs...

  • Page 11: Meter Features

    Figure 2-2. Meter Features METER FEATURES: 1 - SD Card Slot Has SD card installed. External memory card slot for saving configurations and updating firmware WARNING: RISK OF EXPLOSION When loading a system image configuration from an SD Card, ensure that the destination device has the same system voltage, battery profile, and RTS;...

  • Page 12: Features - Interior

    2.4 Features - Interior GenStar MPPT exterior features are shown in Figure 2-3 below. A brief description of each feature follows the figure. 4 5 6 14 15 16 18 19 Figure 2-3. GenStar MPPT Interior Features General Information...
  • Page 13 5 - Battery Voltage Sense Terminals Terminals for battery voltage input provide accurate battery voltage measurement 6 - Remote Temperature Sensor Terminals Connection points for a Morningstar RTS to remotely monitor battery temperature 7 USB-C Port USB-C data / Modbus port...

  • Page 14: Optional Accessories

    2.5 Optional Accessories The following Morningstar accessories are available for purchase separately from your authorized Morningstar dealer: Ground-fault Protection Device (GFPD-600V) The GFPD-600V detects power source ground faults and interrupts current as required by the U.S. National Electrical Code. For a PV array with a maximum open circut voltage less than 150V, a GFPD-150V can be used for ground fault protection.

  • Page 15: Installation And Commissioning

    3.0 INSTALLATION AND COMMISSIONING 3.1 General Installation Notes • Read through the entire installation section first before beginning installation. • Be very careful when working with batteries. Wear eye protection. Have fresh water available to clean any contact with battery acid. •...
  • Page 16 • The GenStar MPPT uses corrosion-resistant fasteners, an anodized aluminum heat sink, and confor- mal coating to protect it from harsh conditions. However, for long service life, extreme temperatures and marine environments should be avoided. • The GenStar MPPT prevents reverse current leakage at night, so a blocking diode is not required in the system.

  • Page 17: Mounting

    3.2 Mounting Refer to Figures 3-1 and 3-2. CAUTION: Risk of Burns Install the GenStar MPPT in a location that prevents casual contact. The GenStar MPPT heatsink can become very hot during operation. GenStar Installation Clearances AT LEAST WARM AIR 6” (150 mm) AT LEAST AT LEAST AT LEAST 1”...
  • Page 18 STEP 3(D) Insert and pull down Figure 3.2 - Hanging GenStar using keyhole slot 1. Choose mounting location A. Locate the GenStar MPPT on a vertical surface that is protected from direct sun, high temperatures, and water. 2. Wiring accessibility and air flow clearance A.

  • Page 19: Overcurrent Protection And Disconnect Switches

    3.3 Overcurrent Protection and Disconnect Switches 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. WARNING: SHOCK AND FIRE HAZARDS Installation must comply with all U.S. National Electrical Code, Canadian Electrical Code or local code requirements.
  • Page 20 Battery breakers or fuses must be sized with a minimum of 125% of the continuous output current rating of the solar controller. Recommended battery circuit fuse or breaker current ratings: Battery Circuit MODEL Breaker/Fuse Rat- GS-MPPT-60M-200V 75 or 80 Amps GS-MPPT-80M-200V 100 Amps GS-MPPT-100M-200V...

  • Page 21: Wiring

    Load Output Overcurrent Protection Devices (OCPD) and Disconnect Switches The output/load breaker or fuse rating must be no greater than 40 Amps. The load fuse or breaker must be sized at a minimum of 125% of the maximum load output current. The maximum load output current is the sum of the branch load circuits or the controller load output current rating.

  • Page 22: Battery Voltage Sense Wires

    For Accessory Wiring, refer to schematic in Figure 3.3 below when following 3.4.1 and 3.4.2 on next pages. BATTERY SENSE (+) (-) 5 Amp fuse Figure 3-3. Accessory installation detail 3.4.1 Battery Voltage Sense Wires Refer to Figure 3-3 above. WARNING: Fire Hazard When connecting Battery Sense Wires, install a 5 Amp fuse in the (+) sense wire, within six inches (150 mm) of the (+) battery terminal.

  • Page 23: Remote Temperature Sensor With Ferrite Choke

    Generally accepted wiring practice is to limit voltage drops between the charger and the battery to 2%. Even properly sized wiring with 2% drop can result in a 0.3 volt drop for 14.4V charging. Voltage drops will cause some undercharging of the battery. The controller will begin 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.

  • Page 24: Installation

    Lithium batteries do not require temperature compensation. Therefore, temperature compensation is disabled for all of the GenStar MPPT lithium battery presets. However, if the lithium battery temperature drops below freezing or becomes very hot during charging, it can cause irreversible harm to the battery. Therefore, where the battery temperature can get excessively low or high, it is important to use the low or high temperature foldback settings together with an RTS.

  • Page 25: Grounding And Ground Fault Interruption

    COMMON NEGATIVES BATT Install ferrite core around PV (+) and (-) wires, PV INPUT then close and lock core EQUIPMENT Battery GROUNDING Breaker Breaker CONDUCTOR IMPORTANT: DO NOT CONNECT SOLAR INPUT UNTIL AFTER THE CONTROLLER HAS BEEN COMMISSIONED GROUNDING ELECTRODE 12V-24-48V CONDUCTOR BATTERY...

  • Page 26: System Grounding

    SYSTEM GROUNDING The DC system should be bonded to ground with a connection to the primary battery circuit. It can be bonded to ground directly or through an AC service panel if there is an inverter installed in the system. For the DC system grounding electrode conductor (GEC) sizing requirements, refer to NEC Section 250.166, or applicable local regulations or code.

  • Page 27: Solar Connections

    CAUTION: EQUIPMENT DAMAGE Locate battery breakers or fused disconnects for easy access and free from hydrogen gas/sulfuric acid fumes. 2. Connect the battery bank and Genstar battery with a positive wire. A. Fit a positive wire between the battery bank (+) post or busbar and the GenStar battery (+) terminal. B.

  • Page 28: Load Connections

    PV array and other power sources in the system before working on ReadyRelay wiring. See Section 2.6 for a brief description of Morningstar ReadyBlock BOS Accessories. To access the ReadyRail and install a ReadyBlock, remove the ReadyBlock cover by loosening the screw at the top of the cover (See Figure 2-1.
  • Page 29 Read Block instructions before joining to GenStar board Figure 3-5. Ready Block Installation - refer to separate Block documentation for complete instructions The GenStar can accommodate up to three (3) ReadyBlocks. Install additional ReadyBlocks in the same manner as the first ReadyBlock. Refer to the ReadyBlock manuals for wiring and communication cable installation instructions.

  • Page 30: Final Connections

    BMS BLOCK NOTES: Only one BMS Block is supported per system. If multiple BMS blocks are present, a system alarm will trigger and a status message will indicate which of the BMS blocks is active for collecting data from a BMS-battery Additonal Notes: •...
  • Page 31 1. Power ON the controller by the battery breaker or fused disconnect switch. 2. Watch and verify that the Charging Status LED lights solid green, and then the three battery state-of- charge (SOC) LEDs blink in sequence (G-Y-R), confirming proper start-up. If they do not light, check the battery polarity (+/–) and battery voltage.

  • Page 32: To Power-Down

    3.4.10 To Power-down WARNING: Equipment Damage ONLY disconnect the battery from the GenStar MPPT AFTER the solar input has been disconnected. Damage to the controller may result if the battery is removed while the GenStar MPPT is charging. 1. OPEN the solar disconnect switch or breaker. 2.
  • Page 33 Initial Set UTC- Power-up Time Local Time Logo Offset SKU-HW- SW Versions Block? Language Battery Select Ethernet Charging Battery Writes? Profile Model 12V, 24V or LVD-LVR LVD-LVR Profile Profile Required? “RTS Required”, is the default setting. Once a unit is commissioned with this default, a subsequent change to, “RTS not required”, necessitates that the unit be re-commissioned via a Factory Reset using the local...
  • Page 34 RTS START-UP and RUN-TIME Behavior Tables Start-Up Behavior RTS Required -YES RTS Required - NO (Default Setting) (Default must be changed in factory reset-new commisioning) RTS not connnected at start-up Fault - no charging Normal Charging using 25 celcius RTS connected at start-up Normal charging using RTS Normal charging using RTS temperatiure...

  • Page 35: Configuration

    4.0 CONFIGURATION 4.1 Adjusting Settings All settings - excluding factory reset and controlling Ethernet writes - can be configured using Morningstar LiveView web pages. See the main LiveView web page for locations and screens. The configuration sections describe all settings details in terms of LiveView screens, and many settings are also accessible within the Setup-Installer Setup on-board meter menus shown below in Figure 4-1.

  • Page 36: Using Morningstar Mobile

    4.1.2 Using Morningstar Mobile (Mobile App) Morningstar Mobile is an app available for use with Android or iOS devices, and can be downloaded to a mobile device from either the Google Play Store (Android) or the Apple App Store (IOS).

  • Page 37: Using The Liveview Ui

    Bluetooth® must be enabled in the Network\ Modbus setup menu to use Morningstar Mobile. See section 4.2.2. The user must have access to the GenStar meter display to pair and connect to the mobile app. The app will prompt the user to verify a 6 digit pin on both the app and on the GenStar meter display during pairing.

  • Page 38: Settings Screen

    4.1.5 Settings Screen The Settings Screen displays all informational and configured system details. The screen is divided into the following areas: • IDs and versions: View firmware and hardware versions, serial number, key, user interface version and UI build date •...

  • Page 39: Date And Time

    Once all settings adjustments have been made for a given setup menu it must be saved before navigating to another setup menu or a different view. If any settings changes have been made in a setup menu without being saved, an “Abandon Changes” prompt will appear. Select Okay to save the new settings or select Cancel to abandon changes to leave the setup menu without saving.

  • Page 40: Time Servers

    GenStar MPPT and sent as a MODBUS TCP/IP response back to the Ethernet network. Wireless Enable Wireless to turn on the Bluetooth® signal and use the Morningstar Mobile app. TCP/IPv4 Adjust Ethernet connection parameters.

  • Page 41: Load Control

    ACTIONS Format SD Card: Format the SD Card (FAT32). WARNING: erases all contents on the card and creates system directories Delete Event Log Data: Delete event log data files from the /EVENTLOG directory only Delete Daily Log Data: Delete Daily Log Data files from the /DAILYLOG directory only Delete Settings File: Delete configuration setting files saved in the /SETTINGS directory Delete Firmware File:...

  • Page 42: Charger

    The following four (4) custom load control options are available to the right of the Custom button in LiveView: 1) Voltage Only - Enables LVD-LVR load control settings 2) State-of-charge (SOC) ONLY - Enables LSOCD-LSOCR load control settings 3) State-of-charge (SOC) and Voltage - Enables both LVD-LVR and LSOCD-LSOCR load control settings 4) Always On - load terminal voltage is never interrupted-disabled After setting State-of-charge (SOC) and Voltage, when either the battery voltage drops below LVD or SOC is below LSOCD, the disconnect process (including LVD/LSOCD warning) will begin.
  • Page 43 • Battery Current Limit, If enabled, the control will limit its net charge current into the battery (Gen- Star net current or Net Shunt battery current if present) to the given limit. If disabled, the control will contribute up to its maximum rated current. •...
  • Page 44 INSTALLER SETUP SETTINGS Maximum Regulation Voltage Sets the absolute maximum battery voltage limit. The charger will not charge above this value regardless of charge stage target voltage or temperature compensation effects. Note that the default Max Regulation Voltage setting is disabled for all presets. Maximum Equalization Current Limit Sets an absolute limit on the amount of Equalization Stage charging current.

  • Page 45: Schedules

    The ReadyRelay is an expansion block that adds AC and DC-rated relay dry contact hardware functionality and firmware control and logic to the Morningstar GenStar MPPT charge controller. The ReadyRelay can be used to provide additional load control, external charging source control and other signaling functionality.
  • Page 46 specifically occurring fault conditions: A. When charging has stopped due to a fault B. When charging has stopped due to high battery voltage C. When Load has disconnected due to a fault D. When the load has been disconnected due to high battery voltage E.
  • Page 47 After a ReadyShunt is installed: 1. Always make sure to update the Firmware to the latest version available (see Section 5.10 Firmware Updates) 2. Access the GenStar unit by opening a LiveView web page - see Section 4.1.3. 3. Go to Installer Setup\ ReadyBlocks, and choose the desired Shunt Block. 4.

  • Page 48: External Source Control (Esc)

    The BMS Block can also interface with lithium batteries for, "closed loop", charging control and data reporting. Closed loop communication and integration is developed and tested in tandem between Morningstar and a limited number of lithium battery manufacturers including the following: • Deka (duration) •...
  • Page 49 ESC SETUP OVERVIEW 1. Set a ReadyRelay for ESC Start/Stop 2. Set ESC Timing Controls 3. Set an ESC Mode (Manual or Custom) 4. If using Custom for automated Start - Stop control a. Select desired Control Criteria option(s) (at least one Emergency or Start Charging) b.
  • Page 50 An example of ESC Timing Controls are displayed in the graph in Figure 4.2 below. EXTERNAL SOURCE CONTROLS TIMING SEQUENCE EXAMPLE (Intervals are met when elapsed time equals required time) START Minimum Time O (Mins) START MIN. RUN Minimum Run-time (Mins) TIMER START STOP...
  • Page 51 There is also a “use factory defaults” option on the right. The factory defaults include an Emergency Charging (Avoid LVD) preset and a Start Charging (Low Battery / Bulk) preset. After selecting a scheduling-control option, select from a drop-down list of presets or “use custom settings”. Note that all presets can be modified after they are selected.
  • Page 52 Once set, a summary of the Start, Stop, Pause or Resume conditions will be displayed in the ESC Card describing the control conditions. For Example: “Start charging when Battery Voltage is less than 23.4V for 5 minutes OR LVD Warning occurs for 1 minute”...

  • Page 53: Meter Display

    Table 4.1 provides all of the ESC Control Condition Presets available for the GenStar MPPT controller. The battery voltages in the table are for a 12V Nominal system (multiply by 2 for 24V or by 4 for 48V). Factory Defaults Start Condition Stop Condition Emergency Charging...

  • Page 54: Operation

    5.1 TrakStar MPPT Technology The GenStar MPPT utilizes Morningstar’s TrakStar Maximum Power Point Tracking technology to extract maximum power from the solar module(s). The tracking algorithm is fully automatic and does not require user adjustment. Trakstar technology will track the array maximum power point voltage (Vmp) as it varies with weather conditions, ensuring that maximum power is harvested from the array through the course of the day.

  • Page 55: Genstar Mppt Charging

    12 Volt Module 12 Volt Module Current vs. Voltage Output Power TrackStar Maximum Typical Battery Power Maximum Voltage Range Point Power Point Traditional Controller Operating Range VOLTAGE VOLTAGE 15 17 15 17 Figure 5.1. Nominal 12 volt solar module I-V curve and output power graph 5.2 GenStar MPPT Charging Charging is completely adjustable to accommodate a variety of battery chemistries.

  • Page 56: Absorption Stage

    Bulk Charging Stage During Bulk charging, the battery is not at 100% state of charge and battery voltage has not yet charged to the Absorption voltage set-point. The controller will deliver 100% of available solar power to recharge the battery. Absorption Stage When the battery has recharged to the Absorption voltage set-point, constant-voltage regulation is used to maintain battery voltage at the Absorption set-point.

  • Page 57: Preparation For Equalization

    absorption voltage so that the electrolyte gases. The green Battery SOC LED will blink rapidly two (2) times per second during equalization charging. The duration of the equalize charge is determined by the selected battery type. See table 5-1 in this section for more details. The Equalization Time is defined as time spent at the equalization set-point.

  • Page 58: Charging Profiles

    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, maintenance-free) to Flooded and Lithium cells. All voltage settings listed are for nominal 12 Volt batteries. Multiply the voltage settings by two (2) or (4), for 24 and 48 Volt systems, respectively.
  • Page 59 Table 5-2 shows all of the high voltage disconnect and reconnect presets for each charging profile. Table 5-3 shows the shared settings that are common to all GenStar charging presets. GenStar MPPT HVD-HVR Preset Charging Settings Charging Profile Solar HVD Solar HVR Battery Type-Preset Volts...

  • Page 60: Charging Variables

    5.2.3 Charging Variables Each charging variable described in this section is graphically illustrated with examples below: Absorption Extension Threshold Extended Absorption Bulk Absorption Float 12.50 V Absorption Extension Voltage time (hrs) 1:00 2:00 3:00 4:00 5:00 6:00 Figure 5-3. Absorption Extension Charging Profile If battery voltage discharges below the Absorption Extension Threshold the previous night, Absorption charging will be extended on the next charge cycle as shown in the example in Figure 5-3 above.
  • Page 61 Float Exit Time-out Voltage Threshold Figure 5-4. Float Exit Time-out Voltage Charging Profile In Figure 5-4 above, the Float Timeout is set for 60 min. A system load turns on at 3:30 hrs during the Float stage and runs for one hour, then turns off at 4:30 hrs. During this time the load current draw is higher than the charge current so there is a net discharge causing the battery voltage to drop.

  • Page 62: Load Control Information

    For Lead-acid presets, the battery bank discharges below 12.0 volts (24.0 volts @ 24 V) the previous night, Float charging stage will be cancelled for the next charge cycle. Figure 5-5 above, illustrates this concept. At 0:00 hrs (dawn), battery voltage is below the Float Cancel threshold voltage. The diagram shows where Float stage would have occurred if Float was not canceled.
  • Page 63 Low Voltage Disconnect/Reconnect Profiles GenStar MPPT offers seven (7) Low Voltage Disconnect/Reconnect (LVD/LVR) Profiles for load control, as seen in Tables 5-4 below. This includes current compensation (mV/A) values. All voltage and mV/A settings listed are for nominal 12 Volt batteries. Multiply the voltage settings by two (2) or (4), for 24 and 48 Volt systems, respectively.

  • Page 64: Factory Reset Procedure

    5.4 Factory Reset Procedure Factory Reset must be done using the on-board meter display. Navigate to Setup\Advanced Setup\Installer Setup, and enter Installer Password 141. Then navigate to Commands\Factory Reset and choose that option. After a factory reset, the unit will need to be re-commissioned. NOTE: RESTORING SETTINGS AFTER A FACTORY RESET If you wish to restore the settings after a factory reset, make sure the settings have been saved to the internal SD card before performing the factory reset.
  • Page 65 LED Display Key G = green Y = Yellow R = red Y - R = yellow and red flashing G / Y = Green and Yellow are both lit at the same time G / Y - R = Green & Yellow both lit, then red flashing sequentially G-Y-R = green, yellow and red flashing sequentially Sequencing LED patterns (faults) repeat until the fault is cleared General LED Indications...
  • Page 66 Factory Default Battery SOC LED Voltage Thresholds Battery SOC LEDs Voltage Threshold battV > 13.3V Green Green / Yellow 13.0V < battV <= 13.3V Yellow 12.65V < battV <= 13.0V Yellow / Red battV <= 12.65V During LVD Note that voltage threshold State-of-Charge LED displays are only approximate indications of battery charge state, and have variable accuracy during charging and discharging.

  • Page 67: Alarms And Faults

    Heatsink Temperature Sensor Open / Shorted The heatsink temperature sensor is damaged. Contact your Authorized Morningstar Dealer for service. High Input Voltage Current Limit The GenStar MPPT will limit the solar input current as the solar array Voc approaches the maximum input voltage rating.
  • Page 68 The Remote Temperature Sensor is not connected to the controller. Use of the RTS is recommended for proper battery charging. Uncalibrated The controller was not factory calibrated. Contact your Authorized Morningstar Dealer for service. READYBLOCK ALARMS A BMS, Shunt or Relay Block can trigger the following alarms on the host which will trigger a disconnection (shutdown) of the charge controller.
  • Page 69 Faults EEPROM Custom Settings Edit Battery Status LED: Flashing red. Battery SOC LEDs: R-Y-G sequencing. A value has been modified in custom settings memory. The controller will stop charging and indicate a fault condition. After all settings have been modified, the controller must be reset with a reboot control command in LiveView or on the display or by removing and then restoring power to the controller.
  • Page 70 SOLID CHARGING STATUS LED with SELF-TEST (R-Y-G) Battery SOC FAULTS Verify that nothing has been miswired. If not, the error is likely critical. the table below lists a few common critical faults. See local meter display (Status Menu) for specific error. Contact an authorized Morningstar dealer for support.

  • Page 71: Liveview Menus

    5.7 LiveView Menus 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. Cards can be rearranged or hidden to suit a user's application preferences.

  • Page 72: System Commands

    charging profiles with Equalization enabled Battery Charger Override normal operation and force the battery charger to a disconnected state. The GenStar MPPT will not charge the battery while the charger is in disconnected state. 5.8.4 System Commands Activate System commands: Reboot Control Software resets the GenStar MPPT.

  • Page 73: Daily Records

    Daily Records Displays the following records for up to 3-4 years in time - depending on how many daily variables are logged: • Battery NET (A-h) • Charging Timers (mins) • Absorption • Float • Equalize • Max. Battery Voltage (V) •...

  • Page 74: Firmware Updates

    To use an SD Card, LiveView or MSLoad , the GenStar MPPT firmware must first be downloaded from the Morningstar website at https://www.morningstarcorp.com/firmware/genstar-mppt-firmware/. The firmware file will download to your computer as a ZIP folder, and will need to be extracted for use. Once extracted, save the GenStar firmware file to an easily accessible location, e.g., desktop.
  • Page 75 Morningstar Mobile App The Morningstar Mobile App includes the latest version of the GenStar firmware when installing or updating the app. See Section 4.1.2 for information about the Morningstar Mobile App. After connecting to the GenStar MPPT controller, select the firmware update icon on the bottom right of the mobile app and follow the directions on the screen to update the firmware.

  • Page 76: Inspection And Maintenance

    5.11 Inspection and Maintenance Table 5-5 below lists the recommended maintenance schedule to keep the GenStar MPPT performing optimally. WARNING: RISK OF ELECTRICAL SHOCK No power or accessory terminals are electrically isolated from DC input, and may be energized with hazardous solar voltage. Under certain fault conditions, battery could become over-charged. Test between all terminals and ground before touching.

  • Page 77: Networking And Communications

    6.0 NETWORKING AND COMMUNICATIONS 6.1 Introduction NOTE: MS-CAN (CANbus) functionality is not available with initial release. The GenStar MPPT provides several communication options. The GenStar MPPT uses a proprietary protocol for the MS-CAN network and the non-proprietary open standard MODBUS and MODBUS TCP/IP protocols for RS-232, EIA-485, and Ethernet networks.

  • Page 78: Morningstar Ms-Can

    Networking and Communications...

  • Page 79: Serial

    Serial Cable Figure 6-2. A serial connection between a PC and the GenStar MPPT Default Serial Port Settings: • 9600 Baud rate • 8 data bits • 1 or 2 stop bits • no parity 6.4 Modbus and ModbusIP via EIA-485 EIA-485 is a networking standard for serial communication between multiple devices on a bus.

  • Page 80: Ethernet

    Data A and Data B to match the characteristic impedances of the communication cables (120Ω for RS-485 single twisted pair, 100Ω for Category 5 Ethernet). For more information on EIA-485 networking, refer to the, “Morningstar Communications Document”, on the Morningstar website at: www.morningstarcorp.com 6.5 Ethernet...

  • Page 81: Simple Network Management Protocol (Snmp)

    6.6 Simple Network Management Protocol (SNMP) SNMP is an IP-based communications protocol. Some uses and advantages include: • favors a centralized system network management • allows simultaneous mass device polling and reporting • allows coil reads and writes • supports an unlimited number of pollable devices •...

  • Page 82: Network Information

    Confirm data inconsistency with other MS monitoring platforms, e.g., MODBUS TCP, HTTP-LiveView, and then ensure the following: • MIB files are current and all reference MIBs are uploaded simultaneously, i.e., MORNINGSTAR.mib, and GenStar MPPT.mib • Each OID references the appropriate data value type listed in the MIB file •...

  • Page 83: Accessing Liveview Web

    Ethernet Cable Figure 6-3. Ethernet network diagrams actory Default Network Settings DHCP Enabled LiveView Web Address http://gsmppt + serial number IP Address 169.254.x.y (with no acknowledgement from the DHCP server) Subnet Mask 255.255.255.0 Gateway 192.168.1.1 Primary DNS Server 169.254.1.1 MODBUS TCP/IP Port MODBUS TCP/IP HTML...

  • Page 84: Troubleshooting

    9 Vdc or greater. If the voltage on the battery terminals of the controller is between 9 and 72 Vdc, and no LEDs are lit, contact your authorized Morningstar dealer for service. If no voltage is measured, check wiring con- nections, fuses, and breakers.
  • Page 85 Controller makes buzzing and humming noises. Solution: No action is required. This is expected due to magnetic resonance and circuit switching. If troubleshooting does not correct the problem, please refer to Morningstar's Warranty Claim Proce- dure in Section 8. GenStar MPPT...

  • Page 86: Warranty & Policies

    E. specifications are needed to receive assistance. F. multi-meter available (for field troubleshooting) After the dealer is contacted, and is not able to assist with warranty claim, contact Morningstar Technical support at support@morningstarcorp.com. Please provide proof of date and place of purchase, and all details listed in preceding paragraph.
  • Page 87 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, DOWN-TIME, GOODWILL OR DAMAGE TO EQUIPMENT OR PROPERTY.

  • Page 88: Technical Specifications

    9.0 TECHNICAL SPECIFICATIONS GS-MPPT-80M-200V GS-MPPT-60M-200V GS-MPPT-100M-200V Electrical: Maximum Battery Charge Current 80 Amps 60 Amps 100 Amps Maximum Input Voltage (Voc) ALL: 200 Volts MPPT Operating Voltage Range ALL: > battery voltage + 1 Volt; < 180 Volts Max. Input Current (Imp/Isc) 56/60 Amps 75/80 Amps 94/100 Amps...
  • Page 89 GENSTAR MPPT - all models Communication-Interfaces: SD Card Yes (8 GB included) USB-C for data RS-232 Port EIA-485 Port Ethernet/RJ-45 Port Controller Area Network (CAN) Bluetooth Low Power Supported Protocols Modbus, ModbusIP, HTTP, SNMP v2c, Bluetooth LE Internal (LiveView): 3 to 4 years daily records; 35,000 to 140,000 Datalogging Capacity &...

  • Page 90: Efficiency Graphs

    Efficiency Graphs GenStar MPPT Efficiency vs Output Power - 12 Volt Charging, 100A - ba�ery @12.8V 100.00% 95.00% 90.00% 85.00% 20 Vmp 80.00% 80 Vmp 120 Vmp 75.00% 160 Vmp 70.00% 65.00% 60.00% 1000 1200 1400 Output Power (Wa�s) GenStar MPPT Efficiency vs Output Power - 24 Volt Charging, 100A - ba�ery @25.6V 100.00% 95.00%...
  • Page 91 GenStar MPPT Efficiency vs Output Power - 48 Volt Charging, 100A - Ba�ery @51.2V 100.00% 98.00% 52 Vmp 96.00% 60 Vmp 94.00% 92.00% 90.00% 88.00% 86.00% 1000 2000 3000 4000 5000 6000 Output Power (Wa�s) GenStar MPPT Efficiency vs Output Power - 48 Volt Charging, 100A - ba�ery @51.2V 100.00% 98.00%...
  • Page 92 Technical Specifications...
  • Page 93 GenStar MPPT...
  • Page 94 Technical Specifications...
  • Page 95 GenStar MPPT...

  • Page 96: Appendix - Wire Sizing Information

    APPENDIX - WIRE SIZING INFORMATION Wire sizing requirements are based on the ampacity (current carrying capacity) of conductors. The NEC includes Ampacity Tables which are used to determine the ampacity for a given wire size as indicated in Section 310.15. GenStar power terminals are rated for 75ºC.
  • Page 97 Minimum Battery Wire Sizing - 75ºC rated copper Wire Size in a raceway, cable, or earth Wire Size in free air Metric Wire Size3 MODEL @30ºC 30º-45ºC @30ºC 30º-45ºC GS-MPPT-60 #4 AWG 3 AWG > 40°C #6 AWG #6 AWG - 25 2 AWG >...
  • Page 98 2% Voltage Drop Chart for 75°C or 90ºC Stranded Copper Wire Maximum 1-way distance (feet), 12 Volt system - multiply values by (2) for 24 Volt, and by (4) for 48V, system Wire Size 100A (AWG) 23.5 26.1 29.4 33.6 39.2 42.8 47.0...
  • Page 99 Maximum 1-way distance (meters), 12 Volt system - multiply values by (2) for 24 Volt, and by (4) for 48V, system Wire Size 100A 10.9 12.7 13.9 15.3 17.0 19.1 21.8 25.5 30.6 38.2 51.0 10.1 11.0 12.1 13.5 15.2 17.4 20.2 24.3...
  • Page 100 FOR CURRENT DETAILED CERTIFICATION LISTINGS, REFER TO: https://www.morningstarcorp.com/support/library Under, “Type”, choose, “Declaration of Conformity (DOC)”, to view a list of product DOCs. GenStar MPPT Morningstar Corporation MODBUS and MODBUS TCP/IP are trademarks of Modbus IDA. ©2024 Morningstar Corporation. All rights reserved. MS-003633 v2.3 Certifications...

This manual is also suitable for:

Genstar gs-mppt-80Genstar gs-mppt-100Genstar gs-mppt-60m-200vGenstar gs-mppt-80m-200vGenstar gs-mppt-100m-200vGenstar mppt gs-mppt-60m ... Show all

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