3.0
GenStar MPPT
11
General Information
10
• The maximum wire size is 1/0 AWG / 53 mm
2
(multi-strand). Torque tightly up to 100 in-lb.
• Stranded wires to be connected to the GenStar MPPT terminals should be prepared first with,
e.g., clamped copper heads, etc. to avoid the possibility of one conductor coming free.
• Verify that the highest temperature compensated solar array open-circuit voltage (Voc) will not
exceed 200V, and that load current will not exceed 30
Amps
.
• Verify that the system battery will maintain voltages between 10-72.
• To achieve greater total charging current, multiple controllers can be installed in parallel on the
same battery bank - sync charging is not available with intial release. Even with sync charging,
each controller in the system must have its own solar array.
• The load terminals of multiple GenStar controllers can only be wired together if the total load
draw does not exceed 30 Amps. See Section 4.4 for further details.
• Base array, charge controller, and battery bank specifications on accepted design-system sizing
principles-recommendations.
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.
Figure 3-1. Required mounting clearance for proper air flow
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AT LEAST
6” (150 mm)
AT LEAST
6” (150 mm)
AT LEAST
3” (75 mm)
AT LEAST
1” (25 mm)
WARM AIR
COOL AIR
GenStar Installation Clearances
[
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
wash and clean any contact with battery acid.
• Use insulated tools and avoid placing metal objects near the batteries.
WARNING:
Equipment Damage or Risk of Explosion
Never install the GenStar MPPT in an enclosure with vented/flooded batteries. Battery
fumes are flammable and will corrode and destroy the GenStar MPPT circuits.
WARNING: Risk of Fire
Over-current protection device
interrupt
ratings must be a minimum of 2kA, 3kA and 5kA
for 12V, 24V, and 48V systems, respectively.
CAUTION:
Equipment Damage
When installing the 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 GenStar MPPT be certain to observe correct polarity when wiring the
battery to the controller battery terminals. THERE IS NO REVERSE BATTERY POLARITY
PROTECTION.
CAUTION:
Equipment Damage
The GenStar MPPT is designed to regulate ONLY solar (photovoltaic) power. Connection
to any other type of power source e.g. wind turbine or generator may void the warranty.
However, other power sources can be connected directly to the battery.
• For indoor use only. Do not install in locations where water can enter the controller.
• CSA C22.2 #107.1 requires the installer to apply the additional label: WARNING: WHEN A
GROUND-FAULT IS INDICATED, BATTERY TERMINALS AND CONNECTED CIRCUITS MAY
BE UNGROUNDED AND HAZARDOUS. per Clause 15.4.1.3 on or adjacent to the battery, in a
location where it is visible prior to removal of guards, opening of a battery enclosure, etc.
• Be certain that battery terminals and other bare live parts of connected circuits are installed in
enclosures or otherwise guarded against inadvertent contact.
• Loose power connections and /or corroded wires may result in resistive connections that melt wire
insulation, burn surrounding materials, or even cause fire. Ensure tight connections and use cable
clamps to secure cables and prevent them from swaying in mobile applications.
• Preset charging profiles are designed for lead acid and 4, 8 or 16 cell Lithium LiFePO4 batteries.
Custom settings can be used for varied charging requirements (see section 5.2.2 for details). Note
that some batteries may not be compatible.
• The GenStar MPPT battery connection may be wired to one battery, or a bank of batteries. The
following instructions refer to a singular battery, but it is implied that the battery connection can
be made to either one battery or a group of batteries in a battery bank.
• The GenStar MPPT uses corrosion-resistant fasteners, an anodized aluminum heat sink, and
conformal coating to protect it from harsh conditions. However, for acceptable 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.
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3.0 INSTALLATION AND COMMISSIONING
