ProStar Bench Testing Instructions

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Morningstar Corporation 17 Oct 2001

ProStar Bench Test Instructions

Morningstar Corporation

Last updated: 17 October 2001

Tools:

Phillips screwdriver

Flat-blade screwdriver

DMM(digital multimeter)

Power supply, 20V 2A or similar

Small Ah 12V battery (~10Ah)

Small 12VDC load (eg. Small 1/3A bulb)

NOTE: All equipment ratings and testing values are for 12/24V ProStars. Multiply all voltage ratings and

values by 4 for 48V controllers

1. Getting Started

A few things to do before we begin.

Disconnect unit from system wiring

 Open disconnects, switch off breakers

 Be careful not to short or damage the controller when removing

Inspect for physical damage to case, heatsink, or protruding components

Remove cover (keep handy to reference terminal positions when wiring during

testing)

 Flip the unit over (face down)

 Remove the 4 screws that secure the black heat sink to the plastic enclosure

 Carefully remove the plastic case

Not necessary to remove external temperature probe if installed

2. Power Up Unit

The controller’s power up routine indicates that the processor is operating and that the controller has not

had a catastrophic failure.

Procedure

Attach a small power supply as battery:

Page 1 of 11 Rev.1.0

Summary of content (11 pages)

PAGE 1
Morningstar Corporation 17 Oct 2001 ProStar Bench Test Instructions Morningstar Corporation Last updated: 17 October 2001 Tools: Phillips screwdriver Flat-blade screwdriver DMM(digital multimeter) Power supply, 20V 2A or similar Small Ah 12V battery (~10Ah) Small 12VDC load (eg. Small 1/3A bulb) NOTE: All equipment ratings and testing values are for 12/24V ProStars. Multiply all voltage ratings and values by 4 for 48V controllers 1. Getting Started A few things to do before we begin.
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Morningstar Corporation 17 Oct 2001 Power supply positive to “Battery +” on the controller Power supply negative to “Battery –“ on the controller + - + POWER SUPPLY - + - + - Wiring Diagram Correct operation - The unit performs a power up sequence: illuminates “Battery Status” LEDS Green Yellow Red illuminates only one “Battery Status” LED corresponding to the batteries state of charge If the unit has a meter, the meter should begin displaying each of the 3 values(Vbatt,Iarray,Iload) The “Charging
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Morningstar Corporation - 17 Oct 2001 An LED on the Meter did not illuminate during a reading o Bad or incorrectly mounted LED o Bad meter connection o Damaged LCD driver 3. Self-Test Routine (Meter Option Only) The self-test routine is special software run by the processor to check internal circuits for correct operation. This step is for units with the digital meter only. Go to step 4 if your unit does not have a meter.
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Morningstar Corporation - 17 Oct 2001 During the self-test routine, it displays an error code(s) “EXX” where XX is a number. o Refer to table 1 below to troubleshoot any errors found. Page 4 of 11 Rev.1.
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Morningstar Corporation 17 Oct 2001 Table 1. Error Summary of Self-Test Error Description Possible Causes Solutions E01 Battery Switch Battery switch in th empty 4 position, in between positons, or switch damaged Use a screwdriver to ensure that one of the 3 battery types is selected.
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Morningstar Corporation 17 Oct 2001 failure Reference voltage too low E11 E12 Internal temp probe shorted Remote temp probe out of range Temp sensor damaged Replace temp sensor with a 2N3904 BJT transistor Temp sensor shorted Inspect for debris, find and fix short Temp sensor leads shorted Remove remote temperature probe, inspect for pinched cable, re-test without probe connected Temp sensor leads damaged Replace probe Reference voltage too low Not a user serviceable failure Defaults to on-b
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Morningstar Corporation 17 Oct 2001 Battery negative terminal to “Battery –“ on the controller Note the status of the “Charging” LED Adjust power supply to ~16V, set current limit to ~1A Turn off power supply Attach the power supply Power supply positive lead to “Solar +” on the controller Power supply negative lead to “Solar –“ on the controller Turn on power supply Measure the “Array +/-“ voltage Measure the “Battery +/-“ voltage + - + POWER SUPPLY - + - + - + - BATTERY Wiring Diagram Correct
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Morningstar Corporation 17 Oct 2001 Failure - The “Charging” LED illuminates as soon as the battery is attached, without a power supply attached o MOSFETS may be damaged in a “shorted” state The “Charging” LED never illuminates after the power supply is attached o MOSFETS may be damaged in an “open” state o Damaged gate drive The measured array voltage is greater than the measured battery voltage o MOSFETS may be damaged in an “open” state or running linear o Damaged gate drive 5.
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Morningstar Corporation 17 Oct 2001 + - + POWER SUPPLY - + - + - + - BATTERY Wiring Diagram Correct Operation - When the battery lead is disconnected, the controller shuts down immediately.(All LEDS turn off) Failure - When the battery lead is disconnected, the controller still operates (LEDS still illuminated) 6. Putting It All Together This last step will check the overall function of the controller, and provides one final check that everything is working properly Procedure 1.
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Morningstar Corporation 17 Oct 2001 3. Watch start-up sequence and observe when the load turns on. 4. Adjust power supply to ~16V, set current limit to ~1A 5. Turn off power supply 6. Attach the power supply 7. Power supply positive lead to “Solar +” on the controller 8. Power supply negative lead to “Solar –“ on the controller 9. Wire a small load to the load terminals of the controller 10.
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Morningstar Corporation - 17 Oct 2001 Press the button and release once more and both the PV and Load are reconnected. Page 11 of 11 Rev.1.