GROUND-FAULT PROTECTION DEVICE 150V MODEL Installation and Operation Manual For the most recent manual updates, please visit our website. e-mail: info@morningstarcorp.com website: www.morningstarcorp.
TABLE OF CONTENTS 1.0 Important Safety Instructions.............................. 1 2.0 Dimensions and Features...................................... 7 3.0 Installation.................................................................. 8 3.1.0 Mounting the GFPD-150V Box................... 8 3.1.1 Paired to a Tristar.................................... 8 3.1.2 Coupling..................................................... 9 3.1.3 Vertical Mounting.................................... 9 3.1.4 Stand-Alone Use....
1.0 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. This manual contains important safety instructions for the GFPD-150V. The instructions shall be followed during installation, operation and maintenance of the Ground-Fault Protection Device. The following symbols are used throughout this manual to indicate potentially dangerous conditions or important safety instructions. CONSERVER CES INSTRUCTIONS. Ce manuel contient des instructions de sécurité importantes pour le GFPD-150V.
WARNING: A battery can present a risk of electrical shock or burn from large amounts of short-circuit current, fire, or explosion from vented gases. Observe proper precautions. CAUTION: When replacing batteries, use properly specified sizes, types, and ratings based on application and system design. CAUTION: Proper disposal of batteries is required. refer to local regulations or codes for requirements.
WARNING: To reduce the risk of electrical shock, do not perform any service other than that specified in the operating instructions, unless you are qualified to do so. Safety Information Read all of the instructions and cautions in the manual before beginning installation. ♦ There are no user serviceable parts inside the GFPD150V. Do not disassemble or attempt to repair the device. ♦ Disconnect all sources of power to the device before installing or adjusting the GFPD-150V.
Installation Safety Precautions ♦ Mount the GFPD-150V indoors. Prevent exposure to the elements and do not allow water to enter the device. ♦ Use insulated tools when working with batteries. ♦ Avoid wearing jewelry during installation. ♦ The battery bank must be comprised of batteries of same type, make, and age. ♦ Do not smoke in the vicinity of the battery bank. ♦ Power connections must remain tight to avoid excessive heating from a loose connection. ♦ Use properly sized conductors.
The GFPD-150V must be installed by a qualified technician in accordance with electrical regulations of the country where the product is installed. Using the GFPD-150V grounding terminal lug (in the wiring compartment), a permanent and reliable conductor to the earth ground must be established. The grounding conductor must be secured against any accidental detatchment. The knock-outs in GFPD-150V wiring compartment must protect wires with conduit or rings.
♦ La cosse de mise à la terre se trouve dans le compartiment de câblage et est identifiée par le symbole ci-dessous: Symbole de la terre ♦ Le GFPD-150V doit être raccordé dans les circuits en courant continu. Ces connexions DC sont identifiées par le symbole ci-dessous: Symbole courant continu Le GFPD-150V doit être installé par un technicien qualifié conformément à la réglementation électrique du pays où le produit est installé.
2.0 DIMENSIONS AND FEATURES 10.60 in. [ 269 mm ] 4.39 in. [ 112 mm] 5.02 in. [ 128 mm ] Figure 1. GFPD-150V Box Dimensions Conduit / Wire Knock-Outs Bi-color LED red and green Four Power Termination Posts (underside) Test / Reset Button Wiring Aperture Breakers Equipment Ground Terminations Case Figure 2.
3.0 INSTALLATION 3.1.0 Mounting the GFPD-150V Box 3.1.1 Paired to a TriStar The GFPD-150V box can be paired with a Morningstar 150V MPPT TriStar charge controller in several ways. A suggested mounting configuration is with the GFPD150V box to the left of the vertically mounted controller with the two small knock-outs and one large knock-out from each unit lining up as shown in Figure 3. Two optional mounting configurations are shown in Figures 4 and 5. Figure 3. Suggested Mounting Figure 4.
3.1.2 Coupling Coupling hardware is provided for joining the two cases using knock-outs as shown below: 3.1.3 Vertical Mounting 1. If TriStar controller has not been installed, refer to TriStar MPPT-150V operator's manual for mounting instructions, and install. 2. Align GFPD-150 box in desired position and mark the four (4) corner mounting hole locations through the wiring box. Remove the GFPD box. 3. Drill 3/32” (2.5 mm) holes at the drill marks.
3.1.4 Stand-Alone Use The GFPD-150V can also be coupled with non-Morningstar charge controllers. Wiring will mirror the procedure described in Section 3.2.2, but connecting to another product’s terminal lugs instead of a TriStar’s. Configuration of the boxes will depend on the application and controller design. 3.2.0 Wiring the GFPD-150V Box WARNING: Verify that the GFPD-150V breakers and the solar and battery disconnect switches (required) are open before wiring the GFPD-150V Box.
Step 3. Crimp the supplied ring terminals on the breaker side ends of the (+) and (-) breaker<->controller conductors. Connect breaker side (+) wire to post (1) (line side), and breaker side (-) wire to post (3) (load side) using the supplied hardware (see Figure 6). Step 4. Connect controller side breaker<->controller wires to controller (+) and (-) solar terminal lugs. Close GFPD-150V breakers. Step 5.
Power Terminals Feedback Signal / C and NO Wires - no polarity. Connected to labeled breaker assembly blades. Trip Signal Wire (typ. of 2). Terminated with insulated 600V 10-32 ring terminal (typ. of 2) Line Side Shunt Post 2 1 Power Posts 1-4 4 3 Shunt Post Load Side Insulated 600V 0.11in. female quick disconnect (typ. of 2) Not for use - no connection should be made here Figure 6.
4.0 GFPD-150V OPERATION 4.1 Ground-Fault Detection Ground-fault protection is used in electrical systems to prevent current from following any unintended paths. It is critical to detect any stray current, and to interrupt (break) the circuit until safe operation can be restored. Any current imbalance between the (+) and (-) conductors of a circuit indicates a ground-fault. Morningstar’s GFPD-150V will detect this condition, and break the circuit on both the (+) and (-) legs, ensuring interruption. 4.
4.3 Test Button Uses The test button can be used for three purposes: 1. With the GFPD-150V in normal mode, pressing the test button conducts a system test that opens the breaker, shows a red solid LED, and sounds the buzzer. 2. When a ground-fault error has occurred, pressing the test button resets the GFPD-150V to the normal condition. 3. When a wiring error / open breaker alarm has occurred, pressing the test button resets the GFPD-150V to the normal condition. 5.0 TROUBLE-SHOOTING 5.
15 CLOSE BREAKER MANUALLY TEST BUTTON PRESSED (System Test) NOTE: IF GF CURRENT STILL PRESENT OR BREAKER OPEN GF ERROR (LED RED FLASHING + BUZZER) TEST BUTTON PRESSED TEST BUTTON PRESSED SYMBOLS: / Sequencing + Simultaneous WIRING ERROR or OPEN BREAKER ALARM (LED RED / GREEN FLASHING) CRITICAL FAULT (LED RED / RED / GREEN / GREEN FLASHING) Figure 8.
6.0 WARRANTY The150V Model Ground-Fault Protection Device is warrantied to be free from defects in material and workmanship for a period of FIVE (5) years from the date of shipment to the original end user. Morningstar will, at its option, repair or replace any such defective products. CLAIMS PROCEDURE Before requesting warranty service, check the Operator’s Manual to be certain that there is a problem with the controller.
7.0 TECHNICAL SPECIFICATIONS ELECTRICAL: ♦ Maximum Solar Voltage................150 vdc ♦ Maximum Solar Current................ 85 adc ♦ GFPD-150V Supply Voltage Range.............................................. 10-72 vdc ♦ Ground-Fault Current Trip Threshold....................................... 300mA +/- 10% ♦ Self-consumption............................ <1W ♦ Transient Surge Protection............
7.0 TECHNICAL SPECIFICATIONS (Cont.) ENVIRONMENTAL: ♦ Operating Temperature Range.....-40°C to +50°C ♦ Storage Temperature Range......... -55°C to +85°C ♦ Humidity Tolerance.........................Up to 100% ♦ Tropicalization................................. PCB Conformal Coating CERTIFICATIONS: ♦ Meets U.S. NEC 690.5 and 690.35(c) requirements for use as a GFPD ♦ ETL Listed to UL 1741 and CSA C22.2 No. 107.
