PROSTAR SOLAR CONTROLLERS OPERATOR’S MANUAL PROSTAR VERSIONS INCLUDED IN THIS MANUAL PS-15 PS-30 PS-15M-48V Rated Solar Current 15A 30A 15A Rated Load Current 15A 30A 15A Max. Solar Input Voltage 30/60V 30/60V System Voltage 120V 12/24V 12/24V 48V Digital Meter Option yes yes standard Positive Ground Option no yes yes 8 Pheasant Run Newtown, PA 18940 USA phone: 215 321 4457 fax: 215 321 4458 email: info@morningstarcorp.
PROSTAR DIMENSIONS 6.01 (153) 5.37 (136) 3.50 (89) 4.14 (105) .18 (4.57) 2.
CONTENTS 1.0 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.0 IMPORTANT SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 3.0 QUICK START INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.0 LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5.0 DIGITAL METER & MANUAL DISCONNECT . . . . . . . . . . . . . . . . 6 5.1 Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.0 GENERAL INFORMATION Thank you for selecting the ProStar solar controller. This second generation ProStar adds new features and protections using highly advanced technology. Morningstar’s patented PWM battery charging algorithm has also been further optimized for longer battery life and improved system performance. Many functions of the ProStar are unique. Although the ProStar is very simple to use, please take the time to read this operator’s manual and become familiar with the controller.
4. Mount the ProStar to a vertical surface. Allow space above and below the controller for air flow. The heat sink MUST be in a vertical (up & down) position. 3. Connect the Battery first. Observe that the Battery Status LEDs blink in sequence one time. Torque all the ProStar terminals tightly, but do not exceed 35 in-ib. 4. Connect the battery Sense. This is recommended, but not required, if the battery is located more than 5 meters from the controller. 5. Connect the Solar.
FAULT INDICATIONS (G = green; Y = yellow; R = red) G/Y/R blinking together – battery select fault R – Y sequencing – high temperature disconnect R – G sequencing – high voltage disconnect R/G – Y sequencing – load short circuit or overload 5.0 DIGITAL METER & MANUAL DISCONNECT A digital meter is available with the ProStar controller as an option.
NOTE: The push button can be used to toggle through the displays faster.The entire self-test takes 30 to 45 seconds. The load will be turned on for 0.1 second and may flash during the test. A short or overload condition could cause a controller restart.
6.0 INSTALLATION INSTRUCTIONS The ProStar is installed in 10 steps. Follow the procedure in section 6.2 for a proper installation and best performance. 6.1 GENERAL INSTALLATION NOTES • The ProStar uses stainless steel fasteners, an anodized heat sink, and conformal coating to protect from harsh conditions. However, for acceptable service life extreme temperatures and marine environments should be avoided.
NOTE: The battery should be connected first. This will activate the controller protection features, and will power the LEDs to guide installation and start-up. STEP 3: Battery Before connecting the battery, measure the battery’s open-circuit voltage. It must be over 8 volts to operate the controller. For 24 volt systems, the battery must be over 15.5 volts or the ProStar will regulate for 12V. The 12/24V auto selection is only done at start-up.
STEP 7: Battery Type Selection Using a small screwdriver, turn the rotary switch to select the Battery Type. There are 3 choices (see section 8.2): 1 = Gel battery 2 = Sealed battery 3 = Flooded battery A proper selection will flash the 3 Status LEDs together: 1 time for Gel, 2 times for Sealed, and 3 times for Flooded. If the rotary switch does not make a good contact with one of the 3 selections, the 3 LEDs will start flashing together and continue until a good contact is made.
7.2 OPERATIONS & FUNCTIONS The solar system operator should become familiar with the following operating functions of the ProStar controller. Refer to the Technical Specifications (section 10.0) for actual setpoints and other parameter values. • 100% Solid State: All power switching is done with FETs. No mechanical relays are used in the controller. • Battery Charge Regulation: The ProStar is a PWM battery charger. See the next section (8.0) for a description of battery charging.
7.4 INSPECTION & MAINTENANCE The following inspections and maintenance tasks are recommended at least two times per year for best controller performance. 1. Confirm that the correct battery type is selected. Turn the rotary switch to another setting and then back to the setting desired, and count the LED flashes. 2. Confirm that the maximum current of the solar array and load does not exceed the ProStar ratings. 3. Tighten all the terminals. Inspect for loose or broken wire connections. 4.
8.0 BATTERY CHARGING INFORMATION The ProStar is an advanced, fully automatic solar battery charger. No adjustments are required except to select the battery type at installation (see section 8.2 below). 4 EQUALIZE NIGHT 1 FULL CHARGE 2 PWM REGULATION 3 FLOAT NIGHT 8.1 PROSTAR CHARGING METHOD The ProStar uses 4 stages of charging for rapid, efficient and safe battery charging. These are shown in the diagram below: 1. Recharging with 100% of available solar energy. 2.
• Battery Sense: Good battery performance requires accurate charging. Voltage drops in the battery power cables can distort the battery charging. The Sense wires eliminate the voltage drops for optimized charging. • Temperature Compensation: Four control setpoints (25°C reference) are compensated for temperature (PWM regulation, float, equalization, high voltage disconnect). The charging is compensated by –5 mV/°C /cell (–30mV/°C for a 12V battery). Compensation is limited to minus 30°C.
9.4 TROUBLESHOOTING The ProStar is assembled with automated equipment, tested with computers, and is protected from faults. It is usually worthwhile to troubleshoot the entire solar system for faults, since the ProStar will generally not be the cause of a problem. Most problems will be caused by wiring connections, batteries unable to hold a charge, or faulty loads. CAUTIONS: 1. Troubleshooting should be done by qualified personnel. 2. A battery can cause serious damage if shorted. 3.
• Check that the proper battery type has been selected. • Disconnect the solar array, and remove the battery wire from the ProStar battery positive (+) terminal. Wait a few seconds and reconnect the battery positive terminal (leaving the solar array disconnected). After start-up, the green CHARGING LED should not be on. Measure the voltage at the SOLAR terminals (with the array still disconnected).
10.0 TECHNICAL SPECIFICATIONS Note: Values are for 12V versions. 24V versions are 2 times (48V are 4 times) the 12V values unless noted otherwise. BATTERY SETPOINTS (@ 25°C) • Accuracy 12V 24V 48V 40 mV 60 mV 80 mV • Min. voltage to operate 12/24V 8V 48 V 15 V • Self-consumption 12/24V 48V 22 / 25 mA 28 mA • LVD Gel 11.4 Sealed 11.4 Flooded 11.4 • LVD reconnect 12.6 12.6 12.6 • PWM regulation 14.0 14.15 14.4 • Float 13.7 13.7 13.7 • Equalization N/A 14.35 14.9 / 15.
