ProStar MPPT TM Solar Charging System Controller Installation, Operation and Maintenance Manual For the most recent manual revisions, see the version at: www.morningstarcorp.com www.morningstarcorp.
DIMENSIONS [inches (centimeters)] 7.88 ( 20.0 ) 1.0 Important Safety Instructions............................ 1 2.0 General Information.... .................................... ..10 6.69 ( 17.0 ) 4.92 ( 12.5 ) 6.69 ( 17.0 ) TABLE OF CONTENTS 2.1 2.2 2.3 2.4 2.5 7.62 ( 19.4 ) Overview...............................................................10 Regulatory Information........................................11 Versions and Ratings................................................13 Features..........
5.0 Troubleshooting...........................................59 5.1 5.2 LED Fault Indications.................................................. .59 Battery Charging and Performance Issues..................64 6.0 Warranty and Policies..................................65 7.0 Technical Specifications............................... 69 8.0 Certifications............................................... 72 Appendix A - Efficiency.........................................73 Appendix B - De-rating Graphs...........
• Read all of the instructions and cautions in the manual before beginning installation. • There are no user serviceable parts inside the ProStar MPPT. Do not disassemble or attempt to repair the controller. WARNING: Risk Of Electrical Shock. NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROM DC INPUT, AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN FAULT CONDITIONS, BATTERY COULD BECOME OVER-CHARGED. TEST BETWEEN ALL TERMINALS AND GROUND BEFORE TOUCHING.
Ground Symbol • This charge controller is to be connected to DC circuits only. These DC connections are identified by the symbol below: Direct Current Symbol The ProStar MPPT controller must be installed by a qualified technician in accordance with the electrical regulations of the country of installation. A means of disconnecting all power supply poles must be provided. These disconnects must be incorporated in the fixed wiring.
WARNING: Risk of Explosion. Proper disposal of batteries is required. Do not dispose of batteries in fire. Refer to local regulations or codes for requirements. 1.0 • Ce contrôleur de charge ne doit être connecté qu’à des circuits en courant continu. Ces connexions CC sont identifiées par le symbole ci-dessous: AVERTISSEMENT: Risque d'Explosion. Au rebut des piles est nécessaire. Ne pas jeter les piles dans le feu. Se référer aux réglementations locales ou des codes pour les exigences.
• Entretien des batteries devrait être effectué ou supervisé, par un personnel bien informé sur les piles et les précautions de sécurité appropriées. • Soyez très prudent quand vous travaillez avec des grandes batteries au plomb. Portez des lunettes de protection et ayez de l’eau fraîche à disposition en cas de contact avec l’électrolyte. • Enlevez les montres, bagues, bijoux et autres objets mé talliques avant de travailler avec des piles.
2.0 GENERAL INFORMATION NOTE: This section contains important 2.
2.3 Versions and Ratings • Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. This Class B digital apparatus complies with Canadian ICES-003. Cet appareil numerique de la classe B est conforme a la norme NMB-003 du Canada. 2.0 • Consult the dealer, or an experienced radio/TV technician for help.
2.4 Features The features of the ProStar MPPT are shown in Figure 2-1 below. An explanation of each feature is provided.
2.5 Optional Accessories NOTE: The use of a Remote Temperature Sensor 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. RM-1 Meter The digital Remote Meter displays system operating information, error indications, and self-diagnostic read-out. Information is displayed on a backlit 4-digit custom LCD display.
3.0 INSTALLATION INSTRUCTIONS 3.1 General Installation Notes WARNING: Equipment Damage or Risk of Explosion Never install the ProStar MPPT in an enclosure with vented/flooded batteries. Battery fumes are flammable and will corrode and destroy the ProStar MPPT circuits. ! CAUTION: Equipment Damage When installing the ProStar MPPT in an enclosure, ensure sufficient ventilation. Installation in a sealed enclosure will lead to over-heating and a decreased product lifetime.
WARNING: Solar and battery fuses or DC breakers are required in the system. These protection devices are external to the ProStar MPPT controller, and must be a maximum of 30 amps for the PS-MPPT-25/M and 50 amps for the PS-MPPT-40/M. AVERTISSEMENT: Protection contre les surintensités minimum cotes d'interruption de périphérique doivent être de 2000 a 12V systèmes et 4000 a pour les systèmes de 24V. 3.2 Configuration The DIP switch block shown in Figure 3.
only done at start-up, and the detected system voltage will never change during operation. Generally, the specfic system voltage is known, and it is best to set DIPs 2,3 accordingly; the auto-detect setting should be used only in rare circumstances. Switches 4, 5, 6: Battery Type Selection NOTE: These settings are general guidelines for use at the operator’s discretion. The ProStar MPPT can be programmed to satisfy a wide range of charging parameters.
3.3 Mounting 3.4 Wiring Inspect the controller for shipping damage. Mount the ProStar MPPT to a vertical surface (4-#8 stainless steel self-tapping screws are included). Tighten the mounting screws, using care not to crack the plastic case. Do not install directly over an easily combustible surface since the heat sink may get hot under certain operating conditions.
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 MPPT version being installed. STEP 2: Battery Voltage Sense Wires Due to connection and cable resistance, voltage drops are unavoidable in power cables that carry current, including the ProStar MPPT battery cables.
STEP 3: Remote Temperature Sensor WARNING: Risk of Fire. If no Remote Temperature Sensor (RTS) is connected, use the ProStar MPPT within 3m (10 ft) of the batteries. Internal Temperature Compensation will be used if the RTS is not connected. Use of the RTS is strongly recommended. All charging settings are based on 25°C (77°F). If the battery temperature varies by 5°C, the charging setting will change by 0.15 Volts for a 12 Volt battery.
The grounding point may be located in the solar, or the battery circuit. For system grounding electrode conductor sizing requirements, refer to the NEC Section 690.47, or applicable local regulations or code. STEP 5: Battery Connections - see diagram below Figure 3-4. Ground Symbol Per IEC 62109, minimum sizes for equipment copper grounding wire are: • ProStar MPPT-25 7 AWG (10 mm2) • ProStar MPPT-40 7 AWG (10 mm2) OR, of the same, or greater, cross-sectional area as the PV wires.
STEP 6: Solar Connections - see diagram below WARNING: Shock Hazard The solar PV array can produce open-circuit voltages in excess of 120 Vdc when in sunlight. Verify that the solar input breaker or disconnect has been opened (disconnected) before installing the system wires. With the solar disconnect open, connect the solar (PV) array wires to the PS-MPPT solar terminals. Use caution, since the solar array will produce current whenever in sunlight.
polarity (+/–) and battery voltage. Next, the green, yellow or red LED will light depending on the battery state-of-charge (SOC). Confirm that one of these LEDs is on before going to the next step. Close the solar disconnect. If the solar input is connected while in sunlight, the charging LED indicator will light. Confirm proper connection by observing the charging LED. Close the load disconnect, and turn the load on, to confirm a proper connection.
An Advantage Over Traditional Controllers Traditional controllers connect the solar module directly to the battery when recharging. This requires that the solar module operate in a voltage range that is below the module’s Vmp. In a 12V system, for example, the battery voltage may range from 10 - 15 Vdc but the module’s Vmp is typically around 17V. Figure 4.1 shows a typical current vs. voltage output curve for a nominal 12V off-grid module. 12 Volt Module Current vs.
The battery must remain in the Absorption charging stage for a cumulative 150-180 minutes, depending on battery type, before transition to the Float stage will occur. However, Absorption time will be extended by 30 minutes if the battery discharges below 12.50 volts (12V system) the previous night. The Absorption set-point is temperature compensated through either the on-board local temperature sensor, or an optional Remote Temperature Sensor (RTS), if connected.
The Equalization set-point is temperature compensated through either the on-board local temperature sensor, or an optional Remote Temperature Sensor (RTS), if connected. Why Equalize? Routine equalization cycles are often vital to the performance and life of a battery - particularly in a solar system. During battery discharge, sulfuric acid is consumed and soft lead sulfate crystals form on the plates.
gel, have charging requirements up to 14.4V (12V battery). Depending on the battery manufacturer’s recommendation, the “boost” cycle for sealed cells can be disabled by setting the equalize setting switch to manual, if required. Battery Charge Settings Preset ProStar MPPT battery charging options are shown in tables 4-1 and 4-2 below. All voltage settings listed are for nominal 12 Volt batteries. Multiply the voltage settings by two (2) for 24 Volt batteries. DIP Switch Settings 4-5-6 Absorp.
If battery voltage discharges below 12.50 volts (25.00 volts @ 24V) the previous night, Absorption charging will be extended on the next charge cycle as shown in figure 4-3 above. Thirty minutes will be added to the normal Absorption duration. Float Cancel Voltage Absorption Bulk Float Time-out Float cancelled this charge cycle Bulk Absorption Float Bulk Absorption 12.10 V Float Cancel Voltage time (hrs) 60 mins. below Float Voltage 2:00 3:00 4:00 5:00 6:00 Figure 4-4.
4.3 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. System loads may be lights, DC appliances, or other electronic devices. The total current draw of all loads must not exceed the ProStar MPPT 25 or 30 Amp maximum load rating. Float Equalize Equalize V Absorp.
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 (LVD) event will occur soon.
NOTES: 1) R flashing is generally a user addressable fault / error 2) R charging status LED ON with heartbeat blink OFF every 5 secs is a critical fault that generally requires service. See, "Solid Charging Status LED with Self-test (R-Y-G) SOC Faults", in Section 5.1. a lighting test. If no faults or reminders are present, the initial press will conduct a lighting test. A lighting test is used to verify correct wiring in the load circuit and / or verify that the lighting components are operational.
air flow or to re-locate the controller to a cooler spot. 4.7 Custom Settings High Input Voltage Current Limit The ProStar MPPT will limit the solar input current as the solar array Voc approaches the maximum input voltge rating. The array Voc should never exceed the 120 volt maximum input voltage - see the array voltage de-rating graph in Appendix. 4.7.1 Programming with the Meter Display Current Limit The array power exceeds the rating of the controller.
4.7.2 Programming in MSView Beyond the preset DIP switch options, the Prostar MPPT's charging profile and all other settings are customizable using MSView PC software available at: www.morningstarcorp.com WARNING: Risk Of Electrical Shock. Hazardous voltage is present at the Meterbus communications port. Use 150V rated, 4 or 6 conductor UL listed telephone cable.
4.7.5 Lighting Control / Programming Overview The ProStar MPPT display has extensive lighting load programmability. With DIP switch 1 ON (up), a dusk-dawn lighting program is enabled, if lighting timing hasn't been programmed in MSView or using the meter; with DIP 1, 4, 5, 6 ON, and the unit programmed, custom timing will be in effect. With DIP 1 OFF (down), all lighting control functions are disabled.
Schedule Maintenance Items 2 weeks after installation Re-tighten power terminal connections to specified torque values. 3 months after installation Re-tighten power terminal connections to specified torque values. Monthly or After Each Equalization Inspect all wiring for damage or fraying. Inspect for nesting insects. Annually Re-tighten all wiring terminal connections to specified torque values. Inspect the system earth grounding for all components.
disconnected. A small overload could take a few minutes to disconnect. The ProStar MPPT will attempt to reconnect the load two (2) times. Each attempt is approximately 10 seconds apart. If the overload remains after two (2) attempts, the load will remain disconnected until power is removed and re-applied. Solar Short Circuit Charging Status LED: OFF. Solar input power wires are short-circuited. Charging automatically resumes when the short is cleared.
Custom Settings Edit Error status LED: Flashing red. Battery status LEDs: R-Y-G sequencing. A value has been modified in custom settings memory. The controller will stop charging and indicate a fault condition. After all settings have been modified, the controller must be 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.
5.2 Battery Charging and Performance Issues Problem: No LED indications, controller does not appear to be powered 6.0 WARRANTY & POLICIES LIMITED WARRANTY Morningstar Solar Controllers and Inverters Solution: With a multi-meter, check the voltage at the battery terminals on the ProStar MPPT. 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.
MORNINGSTAR TECHNICAL SUPPORT POLICIES MORNINGSTAR TECHNICAL SUPPORT POLICIES (Cont.) Morningstar’s Technical Support Group is dedicated to providing unparalleled customer support. MS Support Scope: 1. Determining correct or failed functionality of a Morningstar product or system of Morningstar devices. It is expected that owners/operators will use manuals (including troubleshooting sections) before requesting technical support. ♦ Please visit the Tech Support section at www.morningstarcorp.
WARRANTY CLAIM PROCEDURE 1. Before proceeding, please refer to product manual, including Troubleshooting section. 2. Contacting your authorized Morningstar distributor or dealer from whom you purchased the unit is the first step in the warranty process. Local dealers can often address warranty issues quickly. 3. If supplier is unable to address the issue, please contact Morningstar by e-mail (support@morningstarcorp.
Battery Charging Set-points (@ 25°C): Data & Communications: [multiply voltages by (2) for 24 volt systems] Communication Port Comm. Protocols DIP Switch Settings 4-5-6 Absorp. Stage (volts) 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 off-on-on 14.40 on-off-off 5 - Flooded on-off-on 6 - Flooded on-on-off 7 - L-16 on-on-on 8 - Custom Battery Type 4- AGM/Flooded Equalize Stage (volts) Absorp.
CERTIFICATIONS APPENDIX A - Efficiency Graphs 550 93 Vmp REACH COMPLIANT 500 ® TUVRheinland 31 Vmp ALL COMPONENTS 62 Vmp 600 8.0 CERTIFIED ProStar MPPTTM, MeterBusTM are trademarks of Morningstar Corporation 400 350 300 250 Output Power (Watts) 200 ENs Directives: • Complies with ENs and LVD standards for CE marking • Immunity: EN 61000-4-3: 2006 EN 61000- 4-6: 2009 • Emissions: CISPR 22: 2008 150 • Complies with UL 1741, UL 62109 and CSA-C22.2 No. 107.
700 650 600 550 Battery Current (Amps) 0 80 90 95 100 105 110 115 120 Battery Current vs. Ambient Temperature (12 Volt System) 100Vmp 80Vmp 60Vmp 40Vmp 20Vmp 45 Battery Current (Amps) 400 350 300 250 200 150 100 85 Array Voltage (Volts) 450 500 Output Power (Watts) 750 ProStar MPPT Efficiency 24 Volt System 40 R A N G E ! 800 850 900 93 Vmp 950 1000 1050 1100 1150 Battery Current vs.
2% Voltage Drop Charts for 75°C Solid Copper Wire APPENDIX C - Wire Sizing Charts 2% Voltage Drop Charts for 75°C Stranded Copper Wire Wire Size (AWG) 1-Way Wire Distance (feet), 12 Volt System Wire Size (AWG) 40A 2/0 * 33.6 38.4 44.8 53.8 67.2 89.6 134.4 268.9 1/0 * 26.6 30.4 35.5 42.6 53.3 71.0 106.6 213.1 2 16.8 19.1 22.3 26.8 33.5 44.7 67.0 134.0 4 10.6 12.1 14.1 16.9 21.1 28.1 42.2 84.4 6 6.6 7.6 8.8 10.6 13.2 17.7 26.5 53.0 8 4.2 4.8 5.6 6.7 8.
*Wires sizes larger than 2 AWG (35 mm2) must be terminated at a splicer block located outside of the ProStar MPPT wiring box. Use 2 AWG (35 mm2) or smaller wire to connect to the ProStar MPPT to the splicer block. 2% Voltage Drop Charts for 90°C Stranded Copper Wire Notes: • The specified wire length is for a pair of conductors from the solar or battery source to the controller (1-way distance) • For 24 volt systems, multiply the 1-way length in the table by 2.
*Wires sizes larger than 2 AWG (35 mm2) must be terminated at a splicer block located outside of the ProStar MPPT wiring box. Use 2 AWG (35 mm2) or smaller wire to connect to the ProStar MPPT to the splicer block. 2% Voltage Drop Charts for 90°C Solid Copper Wire 1-Way Wire Distance (feet), 12 Volt System Wire Size (AWG) 40A 35A 30A 25A 20A 15A 10A 5A 2/0 * 41.7 47.7 55.6 66.7 83.4 111.2 166.8 333.6 1/0 * 33.1 37.8 44.1 52.9 66.1 88.2 132.3 264.6 2 20.8 23.8 27.7 33.3 41.
