ProStar MPPT 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 (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.......
Lighting Control / Programming Overview...............56 Lighting Programming Using Meter Display.............57 Low Temperature Foldback.......................................57 Inspection and Maintenance..................................... 58 5.0 Troubleshooting...........................................60 5.1 5.2 LED Fault Indications.................................................. .60 Battery Charging and Performance Issues..................65 6.0 Warranty and Policies.............................
• 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. 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. Le régulateur MPPT ProStar doit être installé par un technicien qualifié conformément aux règlements du pays d'installation électriques.
• 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 2.2 Regulatory 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.
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 3.1 below is used to set the operating parameters for the ProStar MPPT. 3.0 • Stranded wires to be connected to the ProStar MPPT terminals should be prepared first with e.g. clamped copper heads, etc.
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 WARNING: Fire Hazard When connecting Battery Sense Wires, install a 5 Amp fuse in the (+) sense wire, six inches from the (+) battery terminal.
Connecting the voltage sense wires to the RTS terminal will cause an alarm. 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 MPPT. 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.
NOTE: Depending on the country of installation, conductors identified by the color green, or a combination of green/yellow, shall only be used for earthing conductors. Use copper wire to connect the grounding terminal in the case, and other dead metal, to earth ground.
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. A solar dis-connnect is a convenient way to break the PV connection when necessary. DO NOT CLOSE THE BREAKER AT THIS TIME. 120Voc Maximum 40 Volt MODULE BATTERY (-) 40 Volt MODULE 40 Volt MODULE 3.0 BATTERY (+) Fuse or breaker sizing based on required wire ampacity 6 in. (15) cm MAX.
Turn the loads off, and connect the load wires to the load terminals. DO NOT CLOSE THE BREAKER AT THIS TIME.
4.1 TrakStarTM MPPT Technology The ProStar MPPT utilizes Morningstar’s TrakStar Maximum Power Point Tracking technology to extract maximum power from the solar module(s). The tracking algorithm is fully automatic and does not require user adjustment. Trakstar technology will track the array maximum power point voltage (Vmp) as it varies with weather conditions, ensuring that maximum power is harvested from the array through the course of the day.
4.2 Battery Charging 4-Stage Charging VOLTAGE The ProStar MPPT has a 4-stage battery charging algorithm for rapid, efficient, and safe battery charging. Figure 4-2 shows the sequence of stages. ABSORPTION FLOAT NIGHT TIME Figure 4.2. ProStar MPPT Charging Algorithm Bulk Charge Stage During Bulk charging, the battery is not at 100% state of charge and battery voltage has not yet charged to the Absorption voltage set-point.
Equalization Stage WARNING: Risk of Explosion Equalizing vented batteries produces explosive gases. The battery bank must be properly ventilated. ! CAUTION: Equipment Damage Excessive overcharging 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 for too long can be damaging. Review the requirements for the particular battery being used in your system.
Only a long controlled overcharge, or equalization, at a higher voltage can reverse the hardening of sulfate crystals. 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. 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.
Shared Settings Value Units Absorption Extension Voltage 12.50 Volts Absorption Extension Time Absorption Time + 30 minutes Float Exit Time-out 60 minutes Float Cancel Voltage 12.10 Volts Equalize Time-out Equalize Time + 60 minutes - 30 millivolts / °C / 12V Temperature Compensation Co-efficient 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.
Equalize Time-out Float Cancel Voltage Bulk Absorption Bulk Float Equalize Equalize V Absorp. V Float cancelled this charge cycle Equalize timeout 12.10 V Float Cancel Voltage 2:00 3:00 4:00 5:00 6:00 time (hrs) Figure 4.5. Float Cancellation Charging Profile If the battery bank discharges below 12.10 volts (24.20 volts @ 24 V) the previous night, Float charging stage will be cancelled for the next charge cycle. Figure 4-5 above, illustrates this concept.
4.3 Load Control Information 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.
4.4 LED Indications KEY: G = green Y = yellow R = red G - Y - R = flashing sequencially G/Y = flashing together G / Y - R = G and Y flashing together, alternating with R flash 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. 4.4.1. Power-up 4.4.
Lighting Control Mode (DIP 1 ON) • A quick press and release will clear any faults or reminders that are present. A second quick press will then conduct 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. The lighting test will override LVD for 10 minutes - the override duration is not programmable.
4.7 Custom Settings 4.7.1 Programming with the Meter Display The ProStar MPPT is available in metered and non-metered versions. The metered model allows: • Custom programming, including lighting programs and low battery temperature foldback, directly from the unit.
a valid direction in the map. The current location is indicated on the display with a column heading, and a bold descriptor. 4.7.3.2 Adjusting the Meter Display The display setting options, as shown in Figure 4-7, are adjustable by using the directional keys to locate and edit a desired setting or variable. 4.7.4 Using the Meter Display to Program Charging Set-points, Load Control, Communications, and Advanced Settings 4.7.
The High Limit defines the lowest temperature at which the controller will deliver 100% of the controller’s rated output charging current. The Low Limit defines the temperature at which the controller will stop providing battery charging current. The charge current is tapered linearly from the High Limit to the Low Limit. NOTE: Local meter display setup required for Low Limit < 1° Celsius. 4.
5.0 TROUBLESHOOTING 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 OVERCHARGED. TEST BETWEEN ALL TERMINALS AND GROUND BEFORE TOUCHING. AVERTISSEMENT: RISQUE DE CHOC ÉLECTRIQUE. NON ALIMENTATION OU AUX BORNES D'ACCESSOIRES SONT ISOLÉS ÉLECTRIQUEMENT DE L'ENTRÉE DE C.C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION DANGEREUSE SOLAIRE.
A metered model, an RM-1 meter, or MSView PC software, can be used to determine if the RTS is working properly. Battery / Load High Voltage Disconnect (HVD) Error status LED: Flashing red. Battery status LEDs: R-G sequencing. This fault is set when battery voltage is above normal operating limits. The controller will disconnect the solar input and set a High Voltage Disconnect fault.
SOLID CHARGING STATUS LED with SELF-TEST (R-Y-G) SOC FAULTS Verify that nothing has been mis-wired. If not, the error is likely critical. Contact an authorized Morningstar dealer for support.
6.0 MORNINGSTAR TECHNICAL SUPPORT POLICIES WARRANTY & POLICIES LIMITED WARRANTY Morningstar Solar Controllers and Inverters Morningstar’s Technical Support Group is dedicated to providing unparalleled customer support. The ProStar MPPT 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.
WARRANTY CLAIM PROCEDURE 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.
7.0 TECHNICAL SPECIFICATIONS PS-MPPT-25 PS-MPPT-25M PS-MPPT-40 PS-MPPT-40M Electrical: Nominal Battery Voltage All: 12 or 24 Volts Battery Voltage Range All: 10-35 Volts Voltage Accuracy All: 0.1% +/- 50mV Max. Battery Current 25 Amps 40 Amps Max. PV Open-Circuit Voltage All: 120 Volts Load Current Rating 25 Amps 30 Amps Self-Consumption All: ~0.6W (no meter) ~1.
600 550 450 500 93 Vmp 250 300 350 400 Appendices Power-up against any active faults Reverse Polarity - battery and array Solar Short-Circuit Solar High Voltage Disconnect High Heatsink Temperature - Current De-rating High Heatsink Temperature - Load Disconnect Load Short-Circuit Load Over-Current Heatsink Temperature Limit RTS Terminals Battery Sense Terminals Output Power (Watts) Protections 200 2000 meters -40ºC to +60ºC -40ºC to +80ºC 100% n.c.
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.
APPENDIX C - Wire Sizing Charts 2% Voltage Drop Charts for 75°C Solid Copper Wire 1-Way Wire Distance (feet), 12 Volt System 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 35A 30A 25A 20A 15A 10A 5A 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.
*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. 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.
CERTIFICATIONS ALL COMPONENTS ® TUVRheinland CERTIFIED REACH COMPLIANT Registration, Evaluation and Authorization of Chemicals • Complies with UL 1741, UL 62109 and CSA-C22.2 No. 107.1 • IEC 62109-1 • Complies with the U.S.