7.0
Troubleshooting
68
GenStar MPPT
69
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.
WARNING:
Shock Hazard
A means of disconnecting all power supply poles must
be provided. These disconnects must be incorporated
in the fixed wiring. Open all power source disconnects before
removing controller wiring cover, or accessing wiring.
7.1 LED Fault Indications
Battery Over-current
Error status LED: Flashing red. Battery status LEDs: R/Y-G sequencing. While rare, if battery current
exceeds approximately 130% of the controller’s output current rating, this fault can occur. The fault is
generally related to fast, large battery voltage transients (connecting a very heavy or capacitive load
like an inverter) that are faster than the controller can regulate, and it shuts off to protect the circuitry.
The controller will automatically re-start in 10 seconds.
Battery Reverse Polarity
No LED indication, the unit is not powered. No damage to the controller will result. Correct the
miswire to resume normal operation.
Custom Settings Edit
Error status LED: Flashing red. Battery status 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 by removing and then restoring power to
the controller. The new programmed settings will be used after the power reset.
Firmware Update Failure
The firmware update was not successfully programmed. The controller will not indicate the full
power-up LED sequence of G-Y-R when power to the controller is reset. Instead, the controller will
display green, and then stop on yellow. The yellow LED will continue to be lit and the controller will
not complete start up or begin charging.
Re-try the firmware update. The firmware must be successfully loaded before the controller will start
up.
High Heatsink Temperature
Error status LED: Flashing red. Battery status LEDs: R-Y sequencing. The heatsink temperature has
exceeded safe limits 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 LEDs: R-Y-G. If the solar input open-circuit voltage (Voc) exceeds
the 185 Volt maximum rating, the array will remain disconnected until the Voc falls to 175V
High Load Voltage Disconnect (HVD) -
disabled by default
Error status LED: None. Battery status LEDs: R-G sequencing. This fault is set when battery voltage
is above normal operating limits. The controller will disconnect the load output and set a Load High
Voltage Disconnect fault. This fault is designed to protect sensitive loads from excessive voltage.
Recovery occurs at HVD re-connect threshold, if programmed, and the fault will clear automatically.
Load Over-current
Error Status LED: Flashing red. Battery status LEDs: R/Y-G sequencing. If the load current exceeds
the maximum load current rating, the GenStar MPPT will disconnect the load. The greater the
overload the faster the load will be disconnected. A small overload could take a few minutes to
disconnect. The GenStar MPPT will attempt to reconnect the load two (2) times. Each attempt is
approximately 10 seconds apart. If the overload remains after two (2) attempts, the load will remain
disconnected until power is removed and re-applied.
Load Short Circuit
Error status LED: Flashing red. Battery status LEDs: R/G-Y
sequencing. Fully protected against load wiring short-circuits. After two (2) automatic load reconnect
attempts (10 seconds between each attempt) the GenStar MPPT will wait, and then automatically
reconnect the load, once the short is cleared.
Remote Temperature Sensor (RTS)
Error status LED: Flashing red. Battery status LEDs: R/Y - G/Y sequencing. A bad RTS connection or
a severed RTS wire has disconnected the temperature sensor during charging. See Tables 3.5 and
3.6 - in Section 3 - for details on start-up and runtime behabior..
High Battery Voltage Disconnect (HVD)
Error status LED: Flashing red. Battery status LEDs: R-G sequencing. This fault is set when battery
voltage is above normal operating limits. The controller will disconnect the solar input and set a
Battery High Voltage Disconnect fault. This fault is commonly caused by other charging sources in
the system, charging the battery above the GenStar MPPT regulation voltage. Recovery occurs at
HVD re-connect threshold, and the fault will clear automatically.
