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Configuration

35

34

GenStar MPPT 

4.0

For more standard settings infomation, and further custom settings adjustment, expand the Installer 

Setup bar at the bottom of the section.

Battery State-of-Charge (SoC) LED Indications

 

Enter the voltage values that correspond with the desired LED color or combination of colors for that 

voltage.

With a BMS Block installed and configured, battery SoC indications can be based on an actual 

battery SoC percentage.

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.

Maximum Equalization Current Limit -

 sets an absolute limit on the amount of Equalization Stage 

charging current.

Battery High Voltage Disconnect-Reconnect (HVD-HVR) -

 s

et voltages at which charging      

current ceases (HVD) and then resumes (HVR)

Temperature Compensation Coefficient (mV/

º

C) - 

set to

 

adjust the

 

charging set-point to optimize     

charging for different battery temperatures

Minimum Temperature Compensation Limit - 

set the lowest temperature at which temperature 

compenstaion will occur. Temperature compensation will not occur below this temperature.

Maximum Temperature Compensation Limit - 

set the highest temperature at which temperature 

compenstaion will occur. Temperature compensation will not occur above this temperature.

Low-Temperature Current Foldback (0%, 100%) - low and high temperature settings

The GenStar MPPT has a Low Temperature Foldback option which can be used to protect lithium 

batteries from being charged in cold conditions. Use this setting to define the bounds of charge 

current reduction due to low battery temperatures. Configuration can be done in either LiveView or 

the meter display interface, using the Installer Setup Password 141. 
The low temperature-0% limit defines the temperature at which the controller will stop providing 

battery charging current. The high temperature-100% limit defines the lowest temperature at which 

the controller will deliver 100% of the controller’s rated output charging current. Charging current is 

tapered linearly from 100-0% between high and low temperature settings

High-Temperature Current Foldback (100%, 0%) - low and high temperature settings

Use this setting to define the bounds of charge current reduction due to high battery temperatures. 

Using the Installer Setup password, configuration can be done in either LiveView or the meter 

display interface using the Installer Setup Password 141.
The high temperature-0% limit defines the temperature at which the controller will stop providing 

battery charging 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 linearly from 100-0% between low and high temperature settings

1)  Voltage Only - only voltage-related values are adjustable
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. 

Availability 

depends on system configuration

4)  Always On - load terminal voltage is never interrupted-disabled

In Custom overlay #3, the user can enter state-of-charge Disconnect and Reconnect percentages, 

that will disable and enable the load terminal voltage based on battery charge levels. In Custom 

overlays #1 and 3, the user can enter load terminal High Voltage Disconnect and Reconnect (HVD 

and HVR) values that will disable and enable the load terminal voltage based initially on a user        

selected high battery voltage. This setting is useful for batteries that easily damaged with high        

voltage.

4.2.5 Charger 

(Installer Setup)

Also refer to LiveView or meter map for all custom settings options.

Solar Input Mode

MPPT (default)

 

-

 Allow the controller to use its TrakStar Maximum Power Point Tracking algorithm to 

determine the optimal solary array voltage operating point.

Fixed Vmp

 - Disables the MPPT algorithm and uses the specified value as a static source voltage 

operating point.

Voltage to %VOC

 - Disables the MPPT algorithm and instead uses a percentage of measured input 

source open-circuit voltage as the static voltage operating point. Open-circuit voltage (Voc) of the 

input source is measured by the controller periodically.

Battery Bank Info

.

 Define:

•  Battery capacity in Amp-hours. Capacity is used for some charging functions. 
•  Battery current limit, and whether a Shunt Block is required measurement
•  Optional setting to enable a BMS Block for closed-loop battery management
•  Optional setting to require an RTS for temperature compensation

Battery Charge Settings

 

           Warning:  Equipment Damage

   

I       Improper

 

battery charge settings can severely damage batteries. Take great care when   

            applying any charging settings.

See Section 5.2 for descriptions of many charging settings, and, "Installer Setup", below, for 

additional variable descriptions.
Define the charging parameters for the battery. Choose a standard charging preset from a range of 

batteries, OR enter a custom profile if needed. 

Copy to Custom

 copies the values in the Standard 

Profile column to the Custom Profile column. Use this feature to start with a standard charging profile 

that is close to the desired configuration, copy to custom, and then edit the values for a specific 

charging application. 
Preset options are described in Section 5.2.2. Refer to the battery manufacturer's documentation for 

guidance. 

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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