Morningstar REAKSTAR GenStar GS-MPPT-60M-200V Installation, Operation And Maintenance Manual Download Page 1

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Installation, Operation and Maintenance Manu

Solar DC System Controller

Solar Battery Charger & Load Controller

With

TrakStar

Maximum Power Point Tracking Technology

MAXIMUM POWER POINT TRACKING

MODELS

GS-MPPT-60M-200V
GS-MPPT-80M-200V

GS-MPPT-100M-200V

Gen

tar

MPPT™

Summary of Contents for REAKSTAR GenStar GS-MPPT-60M-200V

Page 1: ...nance Manual Solar DC System Controller Solar Battery Charger Load Controller With TrakStarTM Maximum Power Point Tracking Technology MAXIMUM POWER POINT TRACKING MODELS GS MPPT 60M 200V GS MPPT 80M 2...

Page 2: ...y Block Installation 22 3 4 8 Final Connnections 24 3 4 9 Power Up and Verify System Operation 24 3 4 10 Power Down 25 3 5 Commissioning Initial Configuration 25 3 5 1 Methodology 25 3 5 2 Commissioni...

Page 3: ...arging Variables 49 5 3 Load Control Information 52 5 4 Soft key Use 53 Cont 5 5 Factory Reset Procedure 53 5 6 LED Indications 53 5 6 1 General LED Indications 53 5 6 2 Battery Charging LED Indicatio...

Page 4: ...T 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 WARNING THE COMMUNICATIONS PO...

Page 5: ...nnecting battery terminals Determine if battery is inadvertently grounded If so remove the source of contact with ground Contact with any part of a grounded battery can result in electrical shock The...

Page 6: ...d meter key functions Terminals sized for 1 0 AWG 53 5 mm2 wire Digital meter display 5 year warranty see Section 7 0 2 2 Versions and Ratings There are three versions of the GenStar MPPT controller G...

Page 7: ...activation 5 State of charge LEDs General battery state of charge1 2 indicators 1 See future Morningstar ReadyShunt updates for precise battery voltage measurements 2 See Morningstar ReadyBMS accessor...

Page 8: ...data reporting 1 and 2 MS CAN In Out Ports Proprietary Morningstar deWvice communication protocol ports 3 Ethernet Port RJ 45 socket for LAN Internet connection 4 Coin Cell CR 2032 Back up battery for...

Page 9: ...e GenStar MPPT in an enclosure ensure sufficient ventilation Installation in a sealed enclosure will lead to over heating and a decreased product lifetime CAUTION Equipment Damage When installing the...

Page 10: ...ximum voltage of the circuit or higher These devices are external to the GenStar MPPT controller BATTERY OVER CURRENT PROTECTION DEVICE SIZING The U S NEC requires the installation of DC breakers or f...

Page 11: ...zes 8 1 0 AWG 10 50mm2 Load terminal wire sizes 14 6 AWG 2 5 16mm2 Conductor ampacity current carrying capacity must be greater than the maximum current expected in the power circuits Battery breakers...

Page 12: ...ugh conduit with the power conductors Observing correct polarity connect both battery voltage sense wires to the GenStar MPPT at the 2 position Battery Sense terminal and to battery and terminals No d...

Page 13: ...attery temperature varies by just 5 C the charging target regulation voltage should change by 0 15 Volts for a 12 Volt battery This is a substantial change in battery charging so it is important to al...

Page 14: ...nnect 3 4 6 LOAD CONNECTIONS refer to Figure 3 4 above CAUTION Equipment Damage Do not wire any AC inverter to the load terminals of the GenStar MPPT Damage to the load control circuit may result An i...

Page 15: ...tallation and operation instructions As seen in Figure 2 1 and then as described in Section 2 3 A Loosen screw 7 B Remove the cover 9 by pressing in the tabs 10 C Use a knife to cut out the dead panel...

Page 16: ...make the GEC connection at the battery post also STEP 2 Confirm that the PV array wire polarity is correct and that the PV disconnect switch or breaker is in the OPEN position Connect the PV array neg...

Page 17: ...R Table 3 3 GenStar MPPT Start up Behavior Table 3 4 GenStar MPPT Run time Behavior RTS START UP and RUN TIME BEHAVIOR TABLES 12V 24V or 48V BMS Block Battery Charging Profile 1 RTS Required is the de...

Page 18: ...staller Setup on board meter menus shown below in Figure 4 1 CAUTION To effect changes always use the Save Button in upper right corner of the settings area 4 1 1 Using the Meter Display To adjust LCD...

Page 19: ...ernal clock UTC time and date are entered and an offset for local time zone is entered Note that the local offset must be adjusted when a time zone changes to DST and back 4 1 2 Using LiveView LiveVie...

Page 20: ...ar MPPT is connected to a DHCP router and the DHCP option is selected network settings will automatically be assigned To modify inverter settings remotely over Ethernet use the Installer Setup screen...

Page 21: ...harging current The low temperature 100 limit defines the highest temperature at which the controller will deliver 100 of the controller s rated output charging current Charging current is tapered lin...

Page 22: ...ReadyRelay assingments will govern which mode can be used 1 DISABLED External Source Control function is disabled Absorption End Amps set a net current threshold below which the controller will trans...

Page 23: ...GEN 2 MANUAL External Source starting can be triggered manually via Command or Soft key Once a ReadyRelay has been designated as a Command Schedule signal use Commands or Soft key see Section 4 2 7 5...

Page 24: ...ramming Prohibit Charging ONLY On Schedule timing Start Charging Charging 1 2 and 3 can be designated using On Schedule timing Conditions can be customized Low Battery complete Bulk voltage and time C...

Page 25: ...For example a system may have 2 amps of solar current flowing into the GenStar MPPT and five amps of charge current flowing out to the battery The GenStar MPPT does not create current Rest assured th...

Page 26: ...nufacturer for optimal battery charge settings Table 5 2 shows all preset high voltage disconnect and reconnect settings Table 5 3 shows the shared settings that are common to all GenStar charging pre...

Page 27: ...nk once per second during Absorption charging The battery must remain in the Absorption charging stage for a cumulative 150 180 minutes depending on battery type before transition to the Float stage w...

Page 28: ...charging battery age temperature and other factors One very broad guide is to equalize flooded batteries every 1 to 3 months or every 5 to 10 deep discharges Some batteries such as the L 16 group will...

Page 29: ...battery voltage below Float voltage for a combined sixty minutes duration will also force an exit from the Float stage Custom Charging The float exit time out and voltage can also be custom programme...

Page 30: ...lth of the battery LVD set point If the battery discharges to the LVD set point the load will disconnect and a solid red Battery Status LED indication will be displayed General Load Control Notes Do n...

Page 31: ...ack to 0 amps if needed to reduce the heatsink temperature The Appendix B de rating graphs indicate maximum ambient temperatures at which the GenStar MPPT will operate with full rated current as indic...

Page 32: ...pproximately 10 seconds apart If the overload remains after two 2 attempts the load will remain disconnected until power is removed and re applied Remote Temperature Sensor RTS Status LED Flashing red...

Page 33: ...ivate System commands Reboot Control Software resets the GenStar MPPT All controller functions including battery charging and power to the loads will cease until the reboot is complete 5 9 5 External...

Page 34: ...Once extracted save the GenStar firmware file to an easily accessible location e g desktop Serial Firmware Updates For USB C and RS 232 connections the MS Load Firmware Utility must be installed downl...

Page 35: ...for web page and real time clock support Hardware and third party software that supports the MODBUSTM protocol can be used to communicate with a GenStar MPPT Multiple communication ports can be used...

Page 36: ...B and GND wires to GenStar EIA 485 terminals Connect Data A B and GND wires to a desired bus connected controller e g another GenStar NOTE If a desired bus connected EIA 485 compatible controller is...

Page 37: ...ernet network diagrams Ethernet Cable Factory Default Network Settings DHCP Enabled LiveView Web Address http gsmppt serial number1 IP 192 168 1 253 if DHCP is not enabled Subnet Mask 255 255 255 0 Ga...

Page 38: ...its and the load is disconnected The load will automatically reconnect when the heatsink cools to a safe temperature 7 0 TROUBLESHOOTING High Solar Voltage Disconnect Status LED None Battery Status LE...

Page 39: ...ill be limited only to the duration of the original product coverage Morningstar Essentials SeriesTM and SureSineTM inverter products are warrantied to be free from defects in materials and workmanshi...

Page 40: ...8 Volts 12 24 48 Volts 12 24 48 Volts 800 1600 3200 1075 2150 4300 1350 2700 5400 Mechanical 16 45 7 46 Wire Size Range Battery voltage sense and RTS Battery voltage sense and RTS Enclosure IP20 Type...

Page 41: ...size as indicated in Section 310 15 GenStar power terminals are rated for 75 C When wires with a 90 C temperature rating are used with terminals that have a 75 C temperature rating wire ampacity at 7...

Page 42: ...randed 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 AWG 100A 90A 80A 70A 60A 55A 50A 45A 40A 35A 30A 25A 20A 15A 4 01 23 5...

Page 43: ...5 8 1 10 8 16 1 5 1 7 1 9 2 1 2 3 2 6 2 9 3 4 4 1 5 2 6 9 10 1 3 1 4 1 6 1 8 2 2 2 6 3 2 4 3 6 1 3 1 5 1 9 2 6 4 1 0 1 3 1 7 2 5 0 8 1 1 1 Wires sizes larger than 50 mm2 must be terminated at a splice...

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Morningstar REAKSTAR GenStar GS-MPPT-60M-200V, Installation, Operation And Maintenance Manual

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