ProStar 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 (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 Troubleshooting............................................. 55 Alarms...............................................................55 LED Fault Indications........................................ 56 Battery Charging and Performance Issues....... 61 6.0 Warranty and Policies................................... 63 7.0 Technical Specifications................................ 67 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 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. RelayDriver (RD-1) The Relay DriverTM accessory enables the ProStar to control external devices.
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 indcate proper polarity, and a secure connection. 3.2 Configuration Figure 3.1.
3.3 Mounting 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 14.40 150 60 120 28 11.30 12.80 off-on-off 3 - Sealed* 14.30 13.50 14.60 150 60 120 28 11.50 13.00 off-on-on Battery Type 4- AGM/Flooded Equalize Stage (volts) Absorp. Time (mins) Equalize Time (mins) Equalize Timeout (mins) Equalize Interval (days) Equalize Equalize LVD LVR Interval (volts) (days) (volts) Absorp. Stage (volts) 150 11.50 12.
3.4 Wiring 3.0 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 Due to connection and cable resistance, voltage drops are unavoidable in power cables that carry current, including the ProStar battery cables.
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). Connecting the voltage sense wires to the RTS terminal will cause an alarm. A battery voltage sense connection is not required to operate the ProStar controller, but it is recommended for best performance. STEP 3: Remote Temperature Sensor WARNING: Risk of Fire. If no Remote Temperature Sensor (RTS) is connected, use the ProStar within 3m (10 ft) of the batteries.
STEP 4: Grounding NOTE: Depending on the country of installation, conductors identified by the color green, or a combination of green / yellow, shall only be used as earthing conductors. NOTE: Before connecting the battery, measure the open-circuit voltage. It must be over 10 Volts to start the controller. If the system voltage Settings Switches are set to Auto-detect, battery voltage over 15.5V will be detected as a 24V nominal battery, and the unit will charge accordingly.
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 7: Load Connections LOAD (+) STEP 6: Solar Connections 3.0 NOTE: For design purposes, array should be nominal 12V for 12V battery, and nominal 24V for 24V battery.
Insert the load fuse, or close the breaker, and turn the load on to confirm a proper connection. If the load does not turn on, it could be for various reasons: the ProStar is in LVD (red LED on); there is a short circuit in the load (LEDs blinking R/G – Y); there is an overload condition (LEDs blinking R/Y - G); the load is not connected, not working, or turned off. After all connections have been completed, observe the LEDs to make sure the controller is operating normally for system conditions.
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. Certain battery types benefit from a periodic boost charge to stir the electrolyte, level the cell Voltages, and complete the chemical reactions.
flooded batteries every 1 to 3 months or every 5 to 10 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.
DIP Switch Settings 4-5-6 Battery Type Absorp. Stage (volts) Float Stage (volts) Equalize Stage (volts) Absorp. Time (mins) Equalize Time (mins) Equalize Timeout (mins) Equalize Interval (days) off-off-off 1 - Sealed* 14.00 13.50 off-off-on 2 - Sealed* 14.15 13.50 14.40 150 60 120 28 11.30 12.80 off-on-off 3 - Sealed* 14.30 13.50 14.60 150 60 120 28 11.50 13.00 off-on-on 14.40 13.50 15.10 180 120 180 28 11.70 13.20 14.60 13.50 15.30 180 120 180 28 11.90 13.
Float Cancel voltage Float Time-out Bulk Absorption Float SubFloat Bulk Absorption Float V 60 mins. below Float 1:00 2:00 3:00 4:00 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 60 cumulative minutes. In figure 4-3, a system load turns on at 4:00 hrs when the controller is in Float stage, runs for one hour, and turns off at 5:00 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. System loads may be lights, pumps, motors, DC appliances, and other electronic devices. The total current draw of all loads must not exceed the ProStar 15 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 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.
Lighting Control Mode (DIP 1 ON) • A quick press and release of the push-button will clear any faults or reminders that are present. A second quick press will then conduct a five minute lighting test. If no faults or reminders are present, the initial press will conduct the lighting test. A lighting test is used to verify correct wiring in the load circuit, and/or verify that the lighting components are operational.
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/ www.morningstarcorp.com/wp-content/ uploads/2014/02/MS-Comm-Document-2010.pdf 4.5.3 Meter Display Operation 4.5.3.
4.6 Inspection and Maintenance Table 4-6 below, lists the recommended maintenance schedule to keep your ProStar performing optimally. 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. Inspect the battery bank. Look for cracked or bulging cases, and corroded terminals. Monthly, or After Each Equalization 4.0 4.5.
Schedule Monthly, or After Each Equalization Maintenance Items terminals. High Temperature Current Limit For wet cell (flooded type) batteries, make sure the water level is correct. Wet cell water levels should be checked monthly or according to the manufacturer’s recommendations. Inspect all wiring for damage or fraying. Re-tighten all wiring terminal connections to specified torque values. Inspect the system earth grounding for all components.
Uncalibrated The controller was not factory calibrated. Return the controller to an authorized Morningstar dealer for service. 5.2 LED Fault Indications Solar Over-current Load Over-current Error Status LED: Flashing red. Battery status LEDs: R/Y-G sequencing. If the load current exceeds the maximum load current rating, the ProStar will disconnect the load. The greater the overload, the faster the load will be disconnected. A small overload could take a few minutes to disconnect.
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 Sense Cables Issue Error status LED: Flashing red. Battery status LEDs: R/Y - G/Y sequencing. If a fault in the battery sense connection (such as a short-circuit, open circuit or loose terminal) occurs after the battery sense has been working, the LEDs will indicate a failure.
SOLID CHARGING STATUS LED with SELF-TEST (R-Y-G) SOC FAULTS 5.3 Battery Charging and Performance Issues Verify that nothing has been mis-wired. If not, the error is likely critical. Contact an authorized Morningstar dealer for support. Problem: No LED indications, controller does not appear to be powered.
6.0 WARRANTY AND POLICIES Problem: Controller makes buzzing and humming noises. Solution: No action is required. This is expected due to magnetic resonance and circuit switching. 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 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 trouble shooting sections) before requesting technical support. 2. Providing product warranty replacements in accordance with the terms of Morningstar’s warranty policy. 3.
WARRANTY CLAIM PROCEDURE 7.0 TECHNICAL SPECIFICATIONS 1. Before proceeding, please refer to product manual, including the 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.
Lighting Control (DIP 1 ON): Battery Charging Set-points (@ 25°C): [multiply voltages by (2) for 24 Volt systems] 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 14.40 150 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.
APPENDIX A - DERATING Protections Thermal Derate 30 25 Maximum Current (A) 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 PWM Current De-rating 20 15 10 5 0 35 40 45 50 55 60 65 Ambient Temperature (◦C) Figure A-1.
APPENDIX B - Wire Sizing APPENDIX C - CERTIFICATIONS 12 Volt Nominal Wire Chart Amps One-way Wire Distance (feet) Wire Gauge (AWG) 2 4 6 8 10 12 14 16 14 70 35 24 18 14 12 10 9 12 112 56 38 28 23 19 16 14 10 180 90 60 45 36 30 26 23 8 287 143 96 72 57 48 41 36 6 456 228 152 114 91 76 65 57 18 20 8 7 13 11 20 18 32 29 51 46 One-way Wire Distance (meters) Wire Gauge (mm2) 2 21 10 7 5 4 3 3 3 3 32 16 10 8 6 5 4 4 5 53 26 17 13 10 8 7 7 8 85 42 28 21 17 14 12 10 13 139 69 46 34 27 23 19 17
