ProStar TM Solar Charging System Controller Installation, Operation, and Maintenance Manual For the most recent manual revision, see the version at: www.morningstarcorp.com www.morningstarcorp.
DIMENSIONS [inches (millimeters)] TABLE OF CONTENTS 1.0 Important Safety Instructions........................1 SPECIFICATION SUMMARY PS-15 / PS-15M PS-30 / PS-30M Nominal Battery voltage 12 / 24V 12 / 24V Max. PV Open- Circuit Voltage* 30 / 60V 30 / 60V Max. Battery Charging Current 15A 30A Rated Load Current 15A 30A 2.0 2.1 2.2 2.3 2.4 General Information..................................... .. 6 Overview........................................................... 6 Regulatory Information..
TABLE OF CONTENTS (Cont.) 5.0 5.1 5.2 5.3 6.0 Troubleshooting............................................. 56 Alarms...............................................................56 LED Fault Indications........................................ 57 Battery Charging and Performance Issues....... 62 Warranty and Policies................................... 64 7.0 Technical Specifications................................ 68 Appendix A - De-rating...........................................
Installation Safety Precautions • Mount the ProStar indoors. Prevent exposure to the elements and do not allow water to enter the controller. • Install the ProStar in a location that prevents casual contact. The ProStar heatsink can become very hot during operation. • 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.
CAUTION: Do not open or mutilate batteries. Released electrolyte is harmful to skin, and may be toxic. Servicing of batteries should be performed, or supervised, by personnel knowledgeable about batteries, and the proper safety precautions. • Be very careful when working with large lead-acid batteries. Wear eye protection and have fresh water available in case there is contact with the battery acid. • Remove watches, rings, jewelry and other metal objects before working with batteries.
2.0 GENERAL INFORMATION 2.1 Overview • R ated for 12 or 24 Volt systems, and 15 or 30 Amps of charging current • Fully protected with automatic and manual recovery • Seven standard charging programs selectable with DIP switches • Continuous self-testing with fault notification • LED indications and optional meter monitoring • Terminals sized for #6 AWG /16 mm2 wire • Includes battery voltage sense terminals • Optional remote battery temperature sensor • 5-year warranty (see Section 6.
• Re-orient or relocate the receiving antenna. • Increase the separation between the equipment and receiver. • Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. • Consult the dealer, or an experienced radio/TV technician for help. 2.3 Features The features of the ProStar are shown in Figures 2-1, 2.2 and 2.3 below. An explanation of each feature follows. 8 1 2.0 FCC rules.
1 - Charging Status / Error LED Shows charging current and error condition statuses.
NOTE: The use of a Remote Temperature Sensor (RTS) is strongly recommended. Controller location, air flow, and system power can drastically affect the local temperature sensor reading. An RTS will provide optimal charging performance. Ground-fault Protection Device (GFPD-150V) The GFPD-150V detects power source ground faults and interrupts current as required by the US National Electrical Code.
3.0 INSTALLATION INSTRUCTIONS 3.1 General Installation Notes • Read through the entire installation section first before beginning installation. • Do not install in locations where water can enter the controller. • Preset charging profiles are generally designed for lead acid batteries. Custom settings can be used for varied charging requirements (see sections 3.2 and 4.5 for details). Note that some battery types may not be compatible.
WARNING: Minimum over-current protection device interrupt ratings must be 2000A for 12V systems, and 4000A for 24V systems. NOTE: Carefully observe the LEDs after each connection. The LEDs will indicate proper polarity, and a secure connection. 3.2 Configuration Figure 3.1.
3.3 Mounting Battery Charging Set-points (@ 25°C): [multiply voltages by (2) for 24 Volt systems] DIP Switch Settings 4-5-6 Float Stage (volts) off-off-off 1 - Sealed* 14.00 13.50 off-off-on 2 - Sealed* 14.15 13.50 14.40 off-on-off 3 - Sealed* 14.30 13.50 14.60 off-on-on 14.40 13.50 on-off-off 5 - Flooded 14.60 on-off-on 6 - Flooded on-on-off 7 - L-16 on-on-on 8 - Custom 4- AGM/Flooded Equalize Stage (volts) Absorp.
3.4 Wiring 6 in / 150 mm 3.0 2 in / 50 mm 6 in / 150 mm 6 7 5 To load (+) and (-) terminals 3 2 Figure 3-2. Proper Clearances for Passive Cooling To battery for temperature sensing To battery (+) and (-) terminals for voltage sensing 1 To properly sized array To battery (+) and (-) terminals 4 Not used in this illustration Figure 3-3. Wiring the ProStar REFER TO FIGURE 3.
STEP 1: Check Controller Limitations Verify that the highest temperature compensated solar array open-circuit voltage (Voc), and load current do not exceed the ratings of the ProStar version being installed. STEP 2: Battery Voltage Sense Wires WARNING: Fire Hazard When connecting Battery Sense Wires, install a 5 Amp fuse in the (+) sense wire, six inches from the (+) battery terminal.
terminals. No damage will occur if the polarity is reversed, but the controller cannot read a reversed sense voltage. Tighten the connector screws to 5 in-lb (0.56 Nm) of torque. The maximum length allowed for each battery voltage sense wire is 98 ft (30m). NOTE: If the battery input voltage is greater than 5 Volts different than the Battery Sense, due to voltage drops or faulty connections, the Battery Sense input will not be recognized by the ProStar.
NOTE: The RTS cable may be shortened if the full length is not needed. Be sure to re-install the ferrite choke on the end of the RTS if a length of cable is removed. This choke ensures compliance with electromagnetic emissions standards. STEP 5: Battery Connections STEP 4: Grounding For safety, and effective lightning protection, it is recommended, and may be locally required, that the negative conductor of the charging system be properly grounded.
WARNING: Shock Hazard The solar PV array can produce opencircuit voltages of up to 60 Vdc when in sunlight, and this DC voltage is supplied to the Power Conversion Equipment (PCE). Verify that the solar input breaker or disconnect has been opened (disconnected) before installing the system wires. STEP 6: Solar Connections STEP 7: Load Connections NOTE: For design purposes, array should be nominal 12V for 12V battery, and nominal 24V for 24V battery.
all connections have been completed, observe the LEDs to make sure the controller is operating normally for system conditions. If the optional digital meter is used, observe that the display is scrolling with proper voltage and current values. Also, a self- test can be performed with digital meter units. STEP 9: To Power Down CAUTION: Risk of Damage ONLY disconnect the battery from the ProStar AFTER the solar input has been disconnected.
Absorption Stage When the battery has recharged to the Absorption voltage set-point, constant voltage regulation is used to maintain battery voltage at the Absorption set-point. This prevents heating and excessive battery gasing. The battery is allowed to come to full state of charge at the Absorption voltage set-point. The green SOC LED will blink once per second during Absorption charging.
CAUTION: Equipment Damage Excessive over-charging and gasing too vigorously can damage the battery plates and cause shedding of active material from the plates. An equalization that is too high, or too long, can be damaging. Review the requirements for the particular battery being used in your system. 34 Operation Why Equalize? Routine equalization cycles are often vital to the performance and life of a battery - particularly in a solar system.
five to ten deep discharges. Some batteries, such as the L-16 group, will need more frequent equalizations. The difference between the highest cell and lowest cell in a battery can also indicate the need for an equalization. Either the specific gravity or the cell voltage can be measured. The battery manufacturer can recommend the specific gravity or voltage values for your particular battery. Preparation for Equalization First, confirm that all of the system loads are rated for the equalization voltage.
Absorption Extension Battery Charging Set-points (@ 25°C): [multiply voltages by (2) for 24 Volt systems] DIP Switch Settings 4-5-6 Battery Type Absorp. Stage (volts) Float Stage (volts) Equalize Stage (volts) Absorp. Time (mins) off-off-off 1 - Sealed* 14.00 13.50 off-off-on 2 - Sealed* 14.15 13.50 14.40 150 off-on-off 3 - Sealed* 14.30 13.50 14.60 off-on-on 14.40 13.50 15.10 on-off-off 5 - Flooded 14.60 13.50 on-off-on 6 - Flooded 14.
Float Time-out Bulk Float Cancel voltage Absorption Float Bulk Absorption Absorption Bulk Float V 60 mins. below Float Voltage 1:00 2:00 3:00 4:00 Float cancelled this charge cycle 5:00 6:00 time (hrs) After entering Float stage, the controller will only exit Float if the battery voltage remains below Float voltage for sixty cumulative minutes. In figure 4-3, a system load turns on at 3:30 hrs when the controller is in Float stage, runs for one hour, and turns off at 4:30 hrs.
4.2 Load Control Information Equalize Time-out Bulk The primary purpose of the load control function is to disconnect system loads when the battery has discharged to a low state of charge, and reconnect system loads when the battery is sufficiently recharged. The total current draw of all loads must not exceed the ProStar 15 or 30 Amp maximum load rating. Float Equalize Equalize V Absorp. V Equalize timeout Current Compensation: 1:00 2:00 3:00 4:00 5:00 6:00 time (hrs) Figure 4.5.
LVD Warning: As the battery discharges the Battery Status LEDs will transition from green to yellow and then from yellow to flashing red. The flashing red indication is a warning that a low voltage disconnect event will occur soon.
Color Indication Operating State None Off (with heartbeat¹) Night Green On Solid ( with heartbeat² ) Charging Red Flashing Error Red On Solid ( with heartbeat2 ) Critical Error ¹ heartbeat indication flickers the Status LED on briefly every 5 seconds ² heartbeat indication flickers the Status LED off briefly every 5 seconds Table 4.4. Status LED Definitions 4.3.
• Regardless of the DIP 7 setting, press and hold the push-button for 5 seconds to initiate an Equalization (EQ). Lighting Control Mode (DIP 1 ON) • A quick press and release of the push-button will clear any errors or reminders that are present. A second quick press will then conduct a five minute lighting test. If no errors or reminders are present, the initial press will conduct the lighting test.
For metered models, see the included complete meter map insert, also available in the ProStar support documents at: http://www.morningstarcorp.com 4.5.2 Programming in MSView Beyond the preset DIP switch options, the ProStar’s charging profile and all other settings are customizable using MSView PC software available at: http://www.morningstarcorp.com/msview/ All aspects of connection and programming are covered in the Product Connectivity Manual: www.morningstarcorp.
Using either MSView or the meter display, four channels are available for setting timers that can work separately, or in combination. See Section 4.5.6 Lighting Programming Using the Meter Display - for more details. 52 Operation The ProStar MPPT has a Low Temperature Foldback option which can be used to protect lithium batteries from being charged in cold conditions.
4.6 Inspection and Maintenance Schedule Table 4-6 below, lists the recommended maintenance schedule to keep your ProStar performing optimally. Schedule 2 weeks after installation 3 months after installation Re-tighten power terminal connections to specified torque values. Inspect for nesting insects. Annually Re-tighten all wiring terminal connections to specified torque values. Inspect the system earth grounding for all components.
5.0 TROUBLESHOOTING 5.1 Alarms High Temperature Current Limit The ProStar will limit the solar input current if the heatsink temperature exceeds safe limits. Solar charge current will be de-rated (to 0 Amps if needed) to reduce the heatsink temperature. The ProStar is designed to operate at full rated current at the maximum rated ambient temperature. This alarm indicates that there is insufficient airflow and that the heatsink temperature is approaching unsafe limits.
Solar Short Circuit Charging Status LED: OFF. Solar input power wires are short-circuited. Charging automatically resumes when the short is cleared. may not detect that the RTS is connected, and the LEDs will not indicate a fault. A metered model, an RM-1 meter, or MSView PC software can be used to determine if the RTS is working properly. Battery Reverse Polarity No LED indication, the unit is not powered. No damage to the controller will result. Correct the mis-wire to resume normal operation.
reset by removing and then restoring power to the controller. The new programmed settings will be used after the power reset. Firmware Update Failure The firmware update was not successfully programmed. The controller will not indicate the full power-up LED sequence of G-Y-R when power to the controller is reset. Instead, the controller will display green, and then stop on yellow. The yellow LED will continue to be lit and the controller will not complete start up or begin charging.
5.3 Battery Charging and Performance Issues Problem: No LED indications, controller does not appear to be powered. Solution: With a multi-meter, check the voltage at the battery terminals on the ProStar. Battery voltage must be 10 vdc or greater. If the voltage on the battery terminals of the controller is between 10 and 35 vdc, and no LEDs are lit, contact your authorized Morningstar dealer for service. If no voltage is measured, check wiring connections, fuses, and breakers.
6.0 WARRANTY AND POLICIES LIMITED WARRANTY Morningstar Solar Controllers and Inverters The ProStar 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 units.
MORNINGSTAR TECHNICAL SUPPORT POLICIES (Cont.) ♦ Please visit the Tech Support section at www.morningstarcorp.com for any documentation or specification needs before requesting support. The site also offers an array sizing tool (String Selector), product comparison tool (Product Comparator) and articles on solar charging technologies and other design considerations. ♦ Although emergencies do arise when a phone call is necessary, e-mail is the best way to contact us, and will result in the quickest response.
7.0 TECHNICAL SPECIFICATIONS PS-15 PS-15M PS-30 PS-30M Electrical: Nominal Battery voltage 12 or 24 Volts Battery voltage Range 10-35 Volts Voltage accuracy 0.1% +/- 50mV (all) Max. Battery Current 15 Amps 30 Amps Max. PV open-circuit voltage 60 Volts1 Load Current Rating 15 Amps 30 Amps Self Consumption <22mA (no meter) <40mA (meter) LED Indications (1) status, (3) battery SOC Transient Surge Protection 1500 watts (solar, battery, load) Mechanical: Dimensions: 6.01(W) x 4.14(L) x 2.
Lighting Control (DIP 1 ON): Lighting Timer Setting Lighting Test Timer Data & Communications: Communication Port Comm.
APPENDIX B - Wire Sizing APPENDIX A - DERATING 12 Volt Nominal Wire Chart Amps Thermal Derate 30 Maximum Current (A) 25 20 15 10 5 0 50 55 60 65 70 75 Ambient Temperature (◦C) 80 One-way Wire Distance (feet) Wire Gauge (AWG) 2 21 10 7 5 4 3 3 3 2 2 3% voltage drop, Annealed copper wire at 20°C 2 4 6 8 10 12 14 16 18 20 14 70 35 24 18 14 12 10 9 8 7 12 112 56 38 28 23 19 16 14 13 11 10 180 90 60 45 36 30 26 23 20 18 8 287 143 96 72 57 48 41 36 32 29 One-way Wire Distance (meters) Wire Ga
APPENDIX C - CERTIFICATIONS ALL COMPONENTS ® TUVRheinland CERTIFIED • • • • • • • • REACH COMPLIANT Registration, Evaluation and Authorization of Chemicals EN 61000-6-2: 2005/AC:2005 EMC Immunity EN 61000-6-4: 2007 +A1:2011 EMC Emissions Industry Canada: CAN ICES-3 (B)/NMB-3(B) IEC 62109-1: 2010 Safety of Power Converters in PV Systems JAS-ANZ Certification Restriction of Hazardous Substances Directive 2011/65/EU (RoHS 2) Electromagnetic Compatibility Directive 2004/108/ EC FCC (Title 47 of CFR), Part
