Morningstar GenStar GS-MPPT-60 User manual

+ #2
1/8 in (3mm)
3/32" (2.5mm)
Insert
and pull
down
SCAN
TOOLS REQUIRED:
www.morningstarcorp.com GenStar MPPT 4
MOUNTING:
Use mounting template to mark, and drill (3)-1/8 in. screw
hole locations. Drive top screw head to 1/4 in. from flush
with wall. Hang keyhole slot on hanging screw head - see
lower-right illustration. Drive top screw head and (2) lower
screw heads flush with mounting brackets.
3
2
1
WARNING: Shock Hazard
Verify that the solar, load and battery breakers
and/or disconnects remain open (disconnected)
until after all of the system wiring has been completed.
INSTALLATION SAFETY:
Quick Start Guide
Use following URL to register Morningstar GenStar MPPT:
https://www.morningstarcorp.com/product-registration
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
[
Choose an indoor mounting location, with no exposure to
sun or water. When mounting, allow for proper air flow, as
seen in upper-right illustration.
SPECIFICATIONS:
GS-MPPT-60 GS-MPPT-80 GS-MPPT-100
Nominal Battery
Voltage 12-24-48V 12-24-48V 12-24-48V
Maximum PV Open-
circuit Voltage 200V 200V 200V
Nominal Maximum
Output Power 800-1600- 3200W
1075-2150-
4300W
1350-2700-
5400W
Maximum
Recommended PV
Input1
1200-2400-
4800W
1600-3200-
6400W
2000-4000-
8000W
Max. Battery Charging
Current 60A 80A 100A
Rated Load Current 30A 30A 30A
1 150% of
Nominal Maximum Output Power
+
-
12V-24-48V
BATTERY
BATT
(+)
GND
COMMON
NEGATIVES
PV INPUT
PV
(+)
LOAD
(+)
LOAD
(-)
PV
Breaker
Battery
Breaker
Install ferrite core around
PV (+) and (-) wires,
then close and lock core
IMPORTANT: DO NOT CONNECT THE
SOLAR INPUT UNTIL AFTER THE
CONTROLLER HAS BEEN COMMISSIONED
LOAD
(-)
Earth
Ground
Equipment
Grounding
Conductor
Grounding
Electrode
Conductor
+
--
+
+
-- --
--
--
--
--
Install ferrite
core with at
least one
Ethernet wire
loop, then
close and
lock core.
WIRING SCHEMATIC –
see accessory wiring details on p. 5 -
reverse
WIRE SIZE RANGES and TORQUE REQUIREMENTS
Connection Point Wire Size Max. Torque
Power Terminals #8-1/0 AWG
(8.4 - 53.4 mm2)
100 in-lb
(11.3 N-m)
Load Terminals #14-6 AWG
(2.1 - 13.3 mm2)
35 in-lb
(4.0 N-m)
Equipment Grounding
Terminal
#14-#2 AWG
(2.1 - 33.6 mm2)
50 in-lb
(5.6 N-m)
Battery Voltage Sense
Terminals
#24-16 AWG
(0.2 - 1.3 mm2) 5 in-lb (0.56 N-m)
Remote Temperature Sensor INCLUDED 5 in-lb (0.56 N-m)
Solar Charging System Controller
Contact Information:
www.morningstarcorp.com
Phone: [phone]
LEGEND
POSITIVE CONDUCTOR
NEGATIVE CONDUCTOR
INCLUDES: Charge controller; Remote
Temperature Sensor (RTS); SD card inside SD card
holder; (1) one-meter MS-CAN Cable; (3) ferrite
cores; mounting template; (4)-#10 mounting screws
IMPORTANT SAFETY INFORMATION:
WARNING: Shock Hazard
The Morningstar GenStar MPPT must be installed
by a qualified technician in accordance with the electrical
regulations of the installation location.
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 Article 690 of the U.S. National
Electrical Code and depending on the installation location.
CAUTION: This guide must be used with
the full product manual that includes
important information. Read the GenStar
product manual for all specifications, safety, regulatory and
warranty information, and for all required instructions,
installation procedures, configuration, and operation
details.
OPTIONAL ACCESSORIES:
See product manuals at www.morningstarcorp.com/
support/library/
ReadyRelay (RB-Relay-1)
The ReadyRelay is an expansion block that adds AC or
DC relay dry contact hardware functionality and firmware
control and logic to the Morningstar GenStar MPPT
charge controller.
ReadyShunt (RB-Shunt-1)
The ReadyShunt is an expansion block designed to
display measured branch currents, count Amp-hours for
those branches, and allow net maximum charge current
into a battery, but not exceeding the battery’s maximum
charging rate.
ReadyBMS (RB-BMS-1)
The ReadyBMS provides simple visibility of battery
performance, hands-free settings and optimized battery
control. Through the ReadyBMS, the GenStar MPPT will
report any data variable contained in the battery BMS.
FULL MANUAL INSTRUCTIONS:
Pencil
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 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.
CAUTION: Equipment Damage
Ensure sufficient ventilation - see
clearance illustration on p. 3 - and do not
install in a sealed enclosure. Improper
ventilation will result in over-heating and a
decreased product lifetime.
!
CAUTION: Equipment Damage
Power UP Sequence - refer to manual’s
LED Indications Section for full details:
1. Connect Battery/Battery Bank.
2. Connect Solar.
Power DOWN Sequence:
1. Disconnect Solar.
2. Disconnect Battery/Battery Bank.
!
!
GenStar
MPPT™
NOTE: Actual wire routing and
connection hardware components
may vary.

12V, 24V or
48V
BMS
Block?
Battery
Charging
Profile
1 “RTS Required”, is the default setting. Once a unit is
commissioned with this default, a subsequent change to,
“RTS not required”, necessitates that the unit be
re-commissioned via a Factory Reset using the local
meter - Installer Setup\Commands\Factory Reset.
Also see RTS Start-up and Run-time Behavior Tables in
the Commissioning Section of the full manual.
Select
Battery
Model
LVD-LVR
Profile
LVD-LVR
Profile
RTS
Required?1
Local Time
Offset
Set UTC
Time
YES
NO
SKU-HW-
SW Versions
Language
Ethernet
Writes?
MSC
Logo
Initial
Power-up
CONFIGURATION:
All settings - excluding factory reset - can be configured using Morningstar LiveView web pages - see the
main LiveView web page for locations and screens. The product manual configuration sections describe all
settings details in terms of LiveView screens, and many settings are also accessible within the Setup-Installer
Setup on-board meter menus shown below and in Section 4 of product manual.
www.morningstarcorp.com 8
7MS-003634 v4
©2022 Morningstar Corporation. All rights reserved.
6
BATTERY CHARGING PRESETS and LVD-LVR PROFILES
Main Display
History
Settings
Setup and
Installer Setup
Display and
Button
Status
View control counters, solar
input, charging, DC load
control, Ready Blocks, date
and time, network
Can control DC Loads,
Counters, Charging,
System, External Source
Control (ESC) and Ready
Blocks. System commands,
allow controller re-boot and
factory settings reset (in
Installer Setup).
View error-event log, daily
records and historical
graphs
Analogous to LiveView
Settings Screen.
View I.D.s and versions,
charger, network, modes
and profiles, charging and
load states, faults, alarms.
networks, Ready Blocks,
External Source Control
(ESC) Timing Controls
ADJUST:
• LCD contrast, brightness,
backlight enable and timer,
auto-scroll, auto-scroll timer,
auto-return, language,
temperature units
PROGRAM:
• Soft-key commands
• Save and load settings between
charger and PC or SD card (in
Installer Setup)
• Time, date, network settings,
SD Card and Logger
PROGRAM:
• Charging, DC load, solar
input
• Settings for schedules, Ready
Blocks. ESC programming
requires LiveView webpage\
Installer Setup
• Upload new firmware from a
PC or SD Card; save settings to
SD card or PC
Commands
Battery Type-Preset Volts Volts Volts Minutes Minutes Minutes
1 - Sealed 14.10 13.70 Disabled 150 Disabled Disabled
2 - Sealed 14.30 13.70 14.61150 60 120
3 - Sealed / Flooded 14.50 13.60 15.0
1
180 60 120
4 - Sealed / Flooded 14.60 13.50
15.2
1180 120 180
5 - Sealed / Flooded 14.80 13.50 15.4
1
180 120 180
6 - LiFePO4 - Low213.60 13.50 Disabled 180 Disabled Disabled
7 - LiFePO4 - Medium
2
13.90 13.50 Disabled 20 Disabled Disabled
8 - LiFePO4 High214.20 13.50 Disabled 15 Disabled Disabled
LVD LVR
Volts Volts
1 - Lead Acid 11.10 12.60
2 - Lead Acid 11.50 12.80
3 - Lead Acid 11.70 12.90
4 - Lead Acid 12.00 13.20
5 - LiFePO4 12.50 13.15
6 - LiFePO4 12.70 13.25
7 - LiFePO4 12.85 13.30
Load Control
Type-Preset
Equalization
Timeout
Absorption
Voltage
Float
Voltage
Equalization
Voltage
Absorption
Time
Equalization
Time
CAUTION: When installing the GenStar MPPT, refer to product manual Secton 3.1 - General
Installation Notes - and all mandatory Section 3.3 Overcurrent Protection Devices and 3.4 Wiring
ratings, specifications, warnings and cautions.
!
COMMISSIONING:
Commissioning requires the user to enter and confirm important settings required for basic operation. Connect
the battery to initiate the commissioning procedure, and then follow the meter prompts. Do not connect the
solar input until after the controller has been commissioned.
The commissioning flowchart - p. 6 - illustrates the selectable options required to prepare the GenStar-MPPT
for operation or further programming. After commissioning, disconnect and then reconnect the battery to
re-start the unit,
2
connect the solar input. When powering down,
3
disconnect the solar input,
4
disconnect the battery.
1
BATTERY
SENSE (+) (-)
5 Amp fuse
RTS
LUGS
Install ferrite core
with at least one
RTS wire loop,
then close and
lock core.
WIRED ACCESSORY INSTALLATION:
Refer to product manual Section 3.4
- Steps 1 and 2 - for important safety
warnings, and additional information.
5
CHARGING PRESET NOTES:
1For Presets 2-5, an equalization charging stage can be initiated manually using the Start Equalization Command
from the local meter or LiveView. Auto equalization can only be set up using custom settings.
2CAUTION: LiFePO4 settings are for 4, 8 and 16-cell LiFePO4 batteries only.
• Preset temperature compensation co-efficient for sealed or flooded batteries =
-30 Millivolts / °C / 12V -- temp. comp. is disabled for LiFePO4 presets.
• All settings, including charging stage voltages and timing, can be custom
programmed using the local meter or LiveView. LiveView includes
additional advanced custom programming options.
• CAUTION: Equipment Damage
Do not equalize sealed batteries with preset or custom settings unless
recommended by the battery manufacturer. To prevent the possibility of
unintended equalization, use custom settings to disable all equalization.
• CAUTION: Settings may not be compatible with all models of these
battery types.
• All voltage setting values are for 12V systems. Mutiply values by two (2)
for 24 Volt batteries, or by four (4) for 48 Volt systems.
See full manual for complete details on charging settings operation.
LVD-LVR PROFILES