1.

0 Tools and Equipment Required

GenStar MPPT
• 12, 24, or 48V battery bank
TM • Solar panel/array, or other power supply input greater than battery voltage - see Section
Te c h n i c a l D o c u m e n t a t i o n

Functional Testing
8B(1) for specific recommendations.
• Small DC load (<2A) - DO NOT connect motors, compressors, inverters, or pumps to load

Procedure
terminals.
• Multi-meter
• Clamp-type DC ammeter
Operational Verification
v01
2.0 System Information

Record system specifications in the table below:

System voltage (12, 24 or 48V)

Array open-circuit voltage

(Voc)

System grounding (+) or (-)

Solar module make and model

# of modules (per controller)

Total array wattage

(per controller)
Abstract:
Load current (or Wattage)
This document outlines the procedure for verifying correct operation of the
GenStar MPPT controller.
Load description (application)
All GenStar MPPT units are subject to calibration and functional testing at
the factory before shipment. This procedure assumes the same.

CAUTION:
! The following outlined procedures assume a basic working knowledge of
electrical circuits. Exercise the necessary precautions when dealing with live
electrical circuits present in solar energy systems.
page 2 of 6
3.0 Visual Inspection properly regulate battery voltage: FAILURE.

Examine terminals and casings for any signs of water damage, excessive heat, burning, loose F) If the GenStar unit has not yet been commissioned, proceed to Section 6 - Commissioning.
components or infestation - note details for technical support. After commissioning, measure DC voltage across the GenStar load (+) and negative (-) terminals,
and record in 5(F) of Appendix.. This reading should be very close to the GenStar battery terminal
voltage reading recorded in 5(D).
4.0 Pre-Startup Measurements – no connections to the GenStar
If any of the following measurements are out of tolerance, contact Morningstar Technical
6.0 Commissioning
Support for assistance.
Use the meter display to complete the commissioning process as seen below. Then follow the
A) Measure the resistance between both negative (-) terminals. Resistance should be < 0.5 ohms. display prompts to reboot the GenStar.

B) Measure the resistance between battery (+) and negative (-) terminals on GenStar. Confirm no
short-circuit (zero ohm reading).
C) Measure the resistance between solar (+) and negative (-) terminals on GenStar. Confirm no Initial Set UTC-
short-circuit (zero ohm reading). Power-up Time
D) Measure the resistance between load (+) and negative (-) terminals on GenStar. Confirm no
short-circuit (zero ohm reading).
MSC
E) Measure the resistance between load (+) and battery (+) terminals on GenStar. Confirm no short- Logo Local Time
circuit (zero ohm reading). Offset
F) Measure the resistance between load (+) and solar (+) terminals on GenStar. Confirm no short-
circuit (zero ohm reading). SKU-HW-
SW Versions
G) Measure the resistance between battery (+) and solar (+) terminals on GenStar. Confirm no
short-circuit (zero ohm reading). NO BMS YES
Block?
5.0 Startup Measurements Language

A) Measure the DC voltage across the battery bank and record in 5(A) of Appendix
Battery Select
B) Observing correct polarity, connect 12, 24 or 48V battery bank (or a 12, 24, or 48V regulated Ethernet Charging
power supply) to the GenStar battery (+) and negative (-) terminals. Writes? Battery
Profile Model
C) Charge Status LED will illuminate solid green for approx. 3 seconds and then turn OFF. Next, the
battery SOC LED will cycle green-yellow-red one time indicating proper boot up. The LEDs will then
settle on any combination of G, G/Y, Y, Y/R, R depending on battery voltage. NOTE: At least one 12V, 24V or
of the Battery Status LEDs should be ON, and the green Charging Status LED should be OFF. 48V LVD-LVR LVD-LVR
LCD display will turn ON, and briefly display model number, serial number, and hardware and Profile Profile
firmware versions.
D) Measure DC voltage across the GenStar battery (+) and negative (-) terminals, and record in 5(D)
of Appendix. 5(A) and 5(D) readings should match. RTS
1
“RTS Required”, is the default setting. Once a unit is Required?1
E) Measure DC voltage across the GenStar solar (+) and negative (-) terminals and record in 5(E) commissioned with this default, a subsequent change to,
of Appendix. This reading should be less than 1 Volt. If the green Charging Status LED is ON, or “RTS not required”, necessitates that the unit be
battery voltage is measured at solar terminals, the input FETs are damaged and the unit will not re-commissioned via a Factory Reset using the local
meter - Installer Setup\Commands\Factory Reset.

page 3 of 6 page 4 of 6
7.0 Load Verification 9.0 Power-down
NOTE: Load terminal use is optional A) Disconnect solar array from GenStar
A) Re-check DC voltage across the GenStar load (+) and negative (-) terminals. This reading should B) Disconnect battery from GenStar
match 5(F), and be approximately equal to battery voltage in 5(A)(D).
C) Disconnect load from GenStar
B) With the load breaker or fuse holder OPEN, and observing correct polarity, connect small 12V-
2A test load(s) set to OFF. Use one 12V test load in series for each 12V of system voltage, e.g., use
2-12V test loads for a 24V system.
IN CASE OF ANY FAILURE IN PERFORMANCE VERIFICATION, CONSULT
C) CLOSE the load breaker, or insert the fuse, and verify that the load(s) power ON. With the load(s) PRODUCT OPERATOR’S MANUAL, OR MORNINGSTAR TECHNICAL SUPPORT.
ON, measure the voltage at the GenStar load terminals; then measure the voltage at the GenStar
battery terminals. Record these two readings in Appendix - 7(C). These readings should be very close www.morningstarcorp.com
to each other. If the load voltage is greater than 0.25V lower than the battery voltage, the LVD FETs
are damaged: FAILURE.
D) Turn OFF the load(s), or OPEN the load circuit APPENDIX - TEST READINGS
8.0 Charging Verification
5(A) Battery bank voltage:
A) If field-testing with a solar array, measure the array open-circuit voltage, and record the reading
in 8(A) of Appendix. This voltage must be greater than battery voltage in 5(A)(D), and a maximum of 5(D) GenStar battery terminal voltage:
200 Volts. This reading should match that of the system specification section.
Follow (B) Array OR B(1) Power Supply 5(E) GenStar solar terminal voltage:
B) With an OPEN solar breaker or fuse holder, and observing correct polarity, connect the solar array
to the GenStar solar (+) and negative (-) terminals. CLOSE the solar breaker or INSERT the fuse. GO 5(F) GenStar load terminal voltage:
TO (C)
B(1) Depending on system voltage, adjust a regulated power supply to 20, 40 or 80 VDC - for 12, 7(C) GenStar [loaded] load terminal voltage:
24, or 48V nominal systems, respectively. Turn OFF the power supply and then, observing correct
polarity, connect the power supply leads to the GenStar solar (+) and negative (-) terminals. Turn ON GenStar [loaded] battery terminal voltage:
the power supply. GO TO (C)
C) If the battery is not charged, Charging Status LED should light solid green with heartbeat off 8(A) Solar array open-circuit voltage:
every five seconds. At least one of the battery SOC LEDs should be ON, but any combination of
flashing indicates a fault. See product manual Section 7 - Troubleshooting - for details. 8(D) GenStar battery voltage:
D) Measure DC voltage across GenStar battery (+) and negative (-) terminals and record in 8(D) of
Appendix. If the battery is not charged, the GenStar meter will indicate, “Bulk”. If the battery has 8(E) GenStar solar terminal voltage:
reached regulation voltage, the GenStar meter will indicate, “Absorption”.
8(F) Meaured battery charging current:
E) Measure DC voltage across GenStar solar (+) and negative (-) terminals and record in 8(E) of
Appendix. Charging is indicated if this reading is Vmp, or ~70-80% of Voc. Regulation is indicated if
this reading is the array open-circuit voltage, AND Charging Status LED is blinking at 1Hz. 8(G) GenStar display battery charging current:
F) Using a clamp-type DC ammeter, measure battery cable current, and record in 8(F) of Appendix.
G) Check battery charging current seen in GenStar display, and record in 8(G) of Appendix. This
value should match the 8(F) reading.
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