3.0
Installation and Commissioning
20
GenStar MPPT
21
CAUTION: Equipment Damage
Locate battery breakers or fused disconnects for easy access and free from hydrogen
gas/sulfuric acid fumes.
STEP 2:
(A)
Fit a positive wire between the battery bank (+) post or busbar and the GenStar battery (+)
terminal.
(B)
Using a short wire on the battery side, install a correctly sized in-line breaker or fused disconnect
switch in the OPEN position as close to the battery (+) post or busbar as possible.
(C)
Connect the long wire from (A) to the vacant breaker terminal from (B), and then the other end
to the GenStar battery (+) terminal.
(D)
Where GenStar battery terminals are more than five (5) feet from the battery, or where circuits
from these terminals pass through a wall or partition, U.S. NEC requires that overcurrent protection
be provided at the solar controller in addition to providing overcurrent protection at the DC battery
power source.
STEP 3:
(A)
Fit a negative wire between the battery (-) post and GenStar MPPT battery (-) terminal.
(B)
Connect the controller end to the GenStar battery (-) terminal.
DO NOT CONNECT THE
BATTERY END OF THE NEGATIVE WIRE AT THIS TIME.
3.4.5 SOLAR CONNECTIONS -
refer to Figure 3-4 above
WARNING: SHOCK HAZARD
-
LIVE EQUIPMENT GROUND CONNECTION
Keep the PV array (-) wiring disconnected during installation, and when system
wires are exposed.
STEP 1:
Wire the PV array according to NEC Section 690 or applicable local regulations or code.
Use caution, since the solar array will produce current whenever it is in sunlight.
STEP 2:
According to the combiner installation instructions, wire the PV array string (+) wire(s) to
a solar combiner box that includes fuse holders or breakers.
DO NOT INSTALL COMBINER FUSES
OR CLOSE COMBINER BREAKERS AT THIS TIME.
STEP 3:
Fit and connect a positive wire between the GenStar PV input (+) terminal and the
OPEN/DISCONNECTED combiner PV (+) disconnect switch or breaker.
DO NOT CLOSE THE
DISCONNECT AT THIS TIME.
STEP 4:
Fit and connect a negative wire between the GenStar PV (-) input terminal and the PV
(-) busbar or combiner terminal.
DO NOT CONNECT THE THE ARRAY STRING (-) WIRE(S) TO
THE COMBINER BOX AT THIS TIME.
This can be achieved by not connecting the PV (-) MC-4
connectors or the PV (-) wire(s) to the transition box, combiner box or the PV (-) Disconnect.
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 inverter should be wired directly to the battery. If there is a possibility
that any other load will sometimes exceed the GenStar’s maximum load current rating, the device
should be wired directly to the battery or battery bank. If load control is required, contact Morningstar
Technical Support for assistance.
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.
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.
WARNING:
Shock Hazard
When a ground fault is indicated, battery terminals and connected circuits might be
ungrounded and hazardous..
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.
NOTE:
Follow local electrical installation code and use green/yellow, green or transparent
insulated grounding-earthing wire.
EQUIPMENT GROUNDING
Use copper wire to connect the grounding terminal in the case, and other dead metal, to earth
ground. The grounding terminal is identified by the ground symbol on the case, just above the
terminal, as shown below:
Ground Symbol
Recommended minimum sizes for equipment copper grounding wire:
• GenStar MPPT-60 8 AWG (8.37 mm
2
)
• GenStar MPPT-80 6 AWG (13.3 mm
2)
• GenStar MPPT-100 4 AWG (21.1 mm
2
)
3.4.4 BATTERY CONNECTIONS -
refer to Figure 3-4 above
STEP 1:
Before wiring, verify that all system breakers and disconnect switches are in the
OPEN/DISONNECTED position, and that all fuses are removed from their holders.
WARNING: SHOCK HAZARD - LIVE EQUIPMENT GROUND CONNECTION
Keep the battery (-) cable and GEC disconnected from the battery bank
(-) post while installing the system or while system wires are exposed.
