SOLAR CONTROLLERS
Installation, Operation and
Maintenance Manual
www.morningstarcorp.com
Models:
PS-15
PS-15M
PS-30
PS-30M
2 3
SPECIFICATION SUMMARY
PS-15 PS-30
Maximum Solar Input 60V 60V
Rated Solar Current 15A 30A
Rated Load Current 15A 30A
System Voltage 12/24V 12/24V
Digital Meter Option Yes Yes
Positive Ground Option No Yes
CONTENTS
1.0 IMPORTANT SAFETY INFORMATION......................................5
2.0 GENERAL INFORMATION .....................................................16
3.0 QUICK START INSTRUCTIONS ..............................................17
4.0 LED INDICATIONS...................................................................19
5.0 DIGITAL METER & MANUAL DISCONNECT..........................20
5.1 Digital Meter ................................................................. ...20
5.2 Manual Disconnect.............................................................20
5.3 Display Disconnects & Protections.....................................21
5.4 Self-Diagnostics (Self-Test).................................................21
6.0 INSTALLATION INSTRUCTIONS.............................................24
6.1 General Installation Notes.................................................24
6.2 Installation Steps...............................................................26
7.0 OPERATION..............................................................................31
7.1 Operator’s Tasks............................................................. ...31
7.2 Operations and Functions..................................................31
7.3 Protections..........................................................................32
7.4 Inspection and Maintenance........................................... .34
7.5 Telecom Noise Jumper.................................................... .35
4 5
1.0 IMPORTANT SAFETY INFORMATION
SAVE THESE INSTRUCTIONS.
This manual contains important safety, installation, operating
and mantenance instructions for the ProStar PWM solar
controller.
The following symbols are used throughout this manual to
indicate potentially dangerous conditions or mark important
safety instructions:
WARNING: Indicates a potentially dangerous
condition. Use extreme caution when performing this
task.
CAUTION: Indicates a critical procedure for safe and
proper operation of the controller.
NOTE: Indicates a procedure or function that is
important to the safe and proper operation of the
controller.
CONSIGNES IMPORTANTES DE SÉCURITÉ
CONSERVEZ CES INSTRUCTIONS:
Ce manuel contient des instructions importantes de sécurité,
d’installations et d’utilisation du contrôleur solaire ProStar
PWM.
Les symboles suivants sont utilisés dans ce manuel pour
indiquer des conditions potentiellement dangereuses ou des
consignes importantes de sécurité.
CONTENTS (Cont.)
8.0 BATTERY CHARGING INFORMATION...................................36
8.1 ProStar Charging Method ............................................. ...36
8.2 Select Battery Type............................................................ 37
8.3 ProStar Charging Features..................................................37
9.0 TESTING and TROUBLESHOOTING.......................................39
9.1 Self-diagnostics.......................................................... ... .....39
9.2 Technical Support................................................................39
9.3 Testing with a Power Supply................................................39
9.4 Troubleshooting............................................................... .40
10.0 TECHNICAL SPECIFICATIONS.............................................45
11.0 CERTIFICATIONS...................................................................48
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6
AVERTISSEMENT: Indique une condition
potentiellement dangereuse. Faites preuve d’une
prudence extrême lors de la réalisation de cette tâche.
PRUDENCE: Indique une procédure critique pour
l’utilisation sûre et correcte du contrôleur.
REMARQUE: Indique une procédure ou fonction
importante pour l’utilisation sûre et correcte du
contrôleur.
Safety Information
• Read all of the instructions and cautions in the manual
before beginning installation.
• There are no user serviceable parts inside the ProStar .
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.
• External solar and battery disconnects are required.
• Disconnect all sources of power to the controller before
installing or adjusting the ProStar .
• There are no fuses or disconnects inside the ProStar. Do
not attempt to repair.
Informations de Sécurité
• Lisez toutes les instructions et les avertissements figurant
dans le manuel avant de commencer l’installation.
• Le ProStar ne contient aucune pièce réparable par
l’utilisateur. Ne démontez pas ni ne tentez de réparer le
contrôleur.
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 TEN-
SION DANGEREUSE SOLAIRE. SOUS CERTAINES CONDI-
TIONS DE DÉFAILLANCE, LA BATTERIE POURRAIT DEVE-
NIR TROP CHARGÉE. TEST ENTRE TOUTES LES BORNES
ET LA MASSE AVANT DE TOUCHER.
• External solaire et la batterie se déconnecte sont néces-
saires.
• Déconnectez toutes les sources d’alimentation du con-
trôleur avant d’installer ou de régler le ProStar .
• Le TriStar MPPT ne contient aucun fusible ou interrupteur.
Ne tentez pas de réparer.
• Installez des fusibles/coupe-circuits externes selon le
besoin.
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8
Installation Safety Precautions
WARNING: This unit is not provided with a
GFDI device.
This charge controller must be used with an
external
GFDI device as required by the Article 690 of
the National Electrical Code for the installation
location.
• Mount the ProStar indoors. Prevent exposure to the
elements and do not allow water to enter the controller.
• Install the ProStar PWM in a location that prevents
casual
contact. The ProStar PWM 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.
• UL/IEC 62109 certified for use in negative ground or
floating systems only
• Do not smoke near the battery bank.
• Power connections must remain tight to avoid excessive
heating from a loose connection.
• Use properly sized conductors and circuit interrupters.
• The grounding terminal is located in the wiring
compartment and is identified by the symbol below:
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 PWM controller must be installed by a qualified
technician in accordance with the electrical regulations of
the country where the product is installed.
A means of disconnecting all power supply poles must be
provided. These disconnects must be incorporated in the
fixed wiring.
The Prostar PWM negative power terminals are common,
and must be grounded as instructions, local codes, and
regulations require.
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Précautions de Sécurité D’installation
AVERTISSEMENT: L’appareil n’est pas fourni
avec un dispositif GFDI. Ce contrôleur de
charge doit être utilisé avec un dispositif GFDI
externe tel que requis par l’Article 690 du
Code électrique national de l’emplacement de
l’installation.
• Montez le ProStar à l’intérieur. Empêchez l’exposition
aux éléments et la pénétration d’eau dans le contrôleur.
• Installez le PS-PWM dans un endroit qui empêche le con-
tact occasionnel. Le dissipateur de chaleur ProStar PWM
peut devenir très chaud pendant le fonctionnement.
• Utilisez des outils isolés pour travailler avec les batteries.
• Évitez le port de bijoux pendant l’installation.
• Le groupe de batteries doit être constitué de batteries du
même type, fabricant et âge.
• UL/IEC 62109 certifié pour utilisation au négatif à la
masse ou les systèmes flottants seulement.
• Ne fumez pas à proximité du groupe de batteries.
• Les connexions d’alimentation doivent rester serrées
pour éviter une surchauffe excessive d’une connexion
desserrée.
• Utilisez des conducteurs et des coupe-circuits de
dimensions adaptées.
• La borne de mise à la terre se trouve dans le comparment
de câblage et est identifiée par le symbole ci-dessous
estampillé dans le boit:
• 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:
Le contrôleur ProStar PWM doit être installé par un
technicien qualifié conformément aux règlementations élec-
triques du pays où est installé le produit.
Un moyen d’assurer la déconnexion de tous les pôles de
l’alimentation doit être fourni. Cette déconnexion doit être
incorporée dans le câblage fixe.
Les bornes de puissance négative ProStar PWM sont com-
muns et doivent être mise à la terre comme instructions, aux
codes et règlements, exigent.
La fixation de la mise à la terre doit être fixée contre
tout desserrage accdentel. Les ouvertures d’entrée au
compartiment de câblage du ProStar PWM doivent être
protégées avec conduit ou anneaux.
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Battery Safety
WARNING: A battery can present a risk of elec-
trical shock or burn from large amounts of short-
circuit current, fire, or explosion from vented gases.
Observe proper precautions.
AVERTISSEMENT: Une batterie peut présenter a
risque de choc électrique ou de brûlure de
grandes quantités de court-circuit curlouer, incendie ou
explosion de ventilé gaz. Observer précautions
appropriées.
WARNING: Risk of Explosion.
Proper disposal of batteries is required. Do
not dispose of batteries in fire. Refer to local regula-
tions 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.
CAUTION: When replacing batteries, use
properly specified number, sizes, types, and
ratings based on application and system
design.
PRUDENCE: Lorsque le remplacement des
piles, utilisez correctement nombre spécifié,
tailles, types et les évaluations basées sur
conception de système et d’application.
CAUTION: Do not open or mutilate batteries.
Released electrolyte is harmful to skin, and may
be toxic.
PRUDENCE: Ne pas ouvrir ou mutiler les piles.
L’électrolyte est nocif pour la peau et peut être
toxique.
• 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.
• Wear rubber gloves and boots
• Use tools with insulated handles and avoid placing tools
or metal objects on top of batteries.
• Disconnect charging source prior to connecting or
dis-connecting battery terminals.
• Determine if battery is inadvertently grounded. If so,
remove the source of contact with ground. Contact with
any part of a grounded battery can result in electrical
shock. The likelihood of such a shock can be reduced
if battery grounds are removed during installation and
maint enance (applicable to equipment and remote
battery supplies not having a grounded supply circuit).
• Carefully read the battery manufacturer’s instructions
before installing / connecting to, or removing batteries
from, the ProStar PWM.
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• Be very careful not to short circuit the cables connected
to the battery.
• Have someone nearby to assist in case of an accident.
• Explosive battery gases can be present during charging.
Be
certain there is enough ventilation to release the
gases.
• Never smoke in the battery area.
• If battery acid comes into contact with the skin, wash
with
soap and water. If the acid contacts the eye, flood
with fresh water and get medical attention.
• Be sure the battery electrolyte level is correct before starting
charging. Do not attempt to charge a frozen battery.
• Recycle the battery when it is replaced.
• Entretien des batteries devrait être effectué ou supervisé,
par un personnel bien informé sur les piles et les précau-
tions 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.
• Porter des bottes et des gants de caoutchouc
• Utiliser des outils avec poignées isolantes et évitez de
placer des outils ou des objets métalliques sur le dessus
de batteries.
• Débrancher la source de charge avant de brancher ou
dis-reliant les bornes de la batterie.
• Utilisez des outils isolés et évitez de placer des objets
métalliques dans la zone de travail.
• Déterminer si batterie repose par inadvertance. Dans
l’affirmative, supprimer la source du contact avec le sol.
Contact avec n’importe quelle partie d’une batterie mise
à la terre peut entraîner un choc électrique. La probabilité
d’un tel choc peut être réduite si des motifs de batterie
sont supprimés pendant l’installation et maintentretien
(applicable à l’équipement et les fournitures de pile de la
télécommande n’ayant ne pas un circuit d’alimentation
mise à la terre).
• Lisez attentivement les instructions du fabricant de la
batterie avant d’installer / connexion à ou retrait des
batteries du ProStar PWM.
• Veillez à ne pas court-circuiter les câbles connectés à la
batterie.
• Ayez une personne à proximité qui puisse aider en cas
d’accident.
• Des gaz explosifs de batterie peuvent être présents pen
-
dant la charge. Assurez-vous qu’une ventilation suffisante
évacue les gaz.
• Ne fumez jamais dans la zone des batteries
• En cas de contact de l’électrolyte avec la peau, lavez avec
du savon et de l’eau. En cas de contact de l’électrolyte
avec les yeux, rincez abondamment avec de l’eau fraîche
et consultez un médecin.
• Assurez-vous que le niveau d’électrolyte de la batterie est
correct avant de commencer la charge. Ne tentez pas de
charger une batterie gelée.
• Recyclez la batterie quand elle est remplacée.
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2.0 GENERAL INFORMATION
Thank you for selecting the ProStar solar controller.
This second generation ProStar adds new features
and protections using highly advanced technology.
Morningstar’s patented PWM battery charging algorithm
has also been further optimized for longer battery life and
improved system performance.
Many functions of the ProStar are unique. Although the
ProStar is very simple to use, please take the time to
read this operator’s manual and become familiar with the
controller. This will help you to make full use of the many
advantages the ProStar can provide for your solar system.
3.0 QUICK START INSTRUCTIONS
This section provides a brief overview of how to get started
using the ProStar controller. However, please review the entire
manual to ensure best performance and years of trouble-free
service.
CAUTION: Equipment Damage
Do not wire any AC inverter to the load terminals of the
ProStar. Damage to the load control circuit may result.
An inverter should be wired to the battery. If there is a possibility
that any other load will sometimes exceed the Prostar’s maximum
voltage or current limits, the device should be wired directly to
the battery or battery bank. If load control is required, contact
Morningstar Tech Support for assistance.
PRUDENCE : Dommages matériels
Ne pas raccorder n’importe quel convertisseur aux bornes
de la ProStar. Pourrait endommager le circuit de com-
mande de charge. S’il y a une possibilité que n’importe quelle autre
charge dépassera parfois la tension maximale de la Prostar ou limites
de courant, l’appareil doit être câblé directement sur la batterie ou
la batterie. Si le régulateur de charge est nécessaire, contacter le
Support technique de Morningstar d’assistance
1. Verify that the nominal array voltage matches the nominal
battery voltage.
2. Verify that the solar and load currents will not exceed the
ratings of the ProStar version being installed.
3. Verify that the solar input voltage (temperature compensated
Voc) will not exceed the rating for the applicable system
voltage
4. Mount the ProStar to a vertical surface. Allow space above
and below the controller for air flow. The heat sink MUST be in
a vertical (up & down) position.
3. Connect the Battery first. Observe that the Battery Status
LEDs blink in sequence one time. Torque all the ProStar
terminals tightly, but do not exceed 35 in-ib.
4. Connect the Battery Sense. This is recommended, but not
required, if the battery is located more than 5 meters from the
controller.
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5. Connect the Solar. With sunlight, the green Charging LED
will light.
6. Load terminals are provided to connect lights, DC
appliances and other devices directly to the controller. Connect
the Load. If there is a fault, the LEDs will begin blinking. Refer
to section
4.0 of this manual to identify the fault.
7. Select the proper charging for the battery being used.
Turn the rotary switch with a screwdriver to the Battery
Type printed on the label. The Battery Status LEDs will
blink 1, 2 or 3 times depending on the Battery Type
selected.
8. For 12 or 24 Volt systems, the ProStar will automatically
select the system voltage. If the system is 24 Volts,
first confirm that the battery is above 15.5 Volts. The
controller selects 12 or 24 Volts at start-up.
9. Observe the LEDs and digital meter (if provided) to con
firm normal operation.
10. It is recommended that the system be properly
grounded.
4.0 LED INDICATIONS
The four LEDs in the lower label indicate system status and
various faults. These functions are described below.
CHARGING (LED 1 – green)
ON: Battery charging during sunlight (always on during
sunlight)
OFF: Normal during night (off during sunlight indicates
solar reverse polarity or overcurrent)
BATTERY STATUS (LEDs 2 – 4)
GREEN: ON indicates battery is near full charge BLINKING
indicates PWM charging (regulation)
YELLOW: ON indicates battery at middle capacity
RED: BLINKING indicates a low charge state and low volt-
age disconnect (LVD) warning ; SOLID indicates that the
load has been disconnected (LVD)
FAULT INDICATIONS
G = green
Y = yellow
R = red
G/Y/R blinking together = battery select fault
R – Y sequencing = high temperature disconnect
R – G sequencing = high voltage disconnect
R/G – Y sequencing = load short circuit or overload
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5.0 DIGITAL METER and MANUAL
DISCONNECT
A digital meter is available with the ProStar controller as an
option. If your version includes the meter display, this sec-
tion will describe the information that can be displayed with
the meter, and the added capabilities that are enabled by
the push-button switch.
5.1 DIGITAL METER
A precision 3-digit digital meter will continuously display
battery voltage, solar current, and the load current. The me-
ter automatically scrolls through these 3 displays. The 3 red
LEDs will indicate which parameter is being displayed.
The digital meter will operate from –30°C to +85°C. The
values displayed are calibrated electronically in production
and are accurate to within a few percent. Please note, how-
ever, that if the Battery Sense is not connected, the voltage
displayed will be in error by the voltage drops in the battery
wires.
5.2 MANUAL DISCONNECT
The push-button next to the digital display can disconnect
the Load or both Load and Solar.
A second push of the button will return the controller back
to normal operation.
LOAD OFF: A brief push of the button (less than 2 seconds)
will disconnect the Load. The Solar remains on and charging.
LOAD AND SOLAR OFF: If the button is held down for 2
seconds, the Solar will also be disconnected.
When the button is pushed, the red LED inside the cap
will light. In addition, the Load or both Load and Solar
will display “OFF“ in the digital meter to indicate the
disconnected state.
5.3 DISPLAY DISCONNECTS & PROTECTIONS
The following protection functions and disconnect condi-
tions will be displayed in the digital meter when they
occur:
LVD – Low Voltage load Disconnect (load only)
HVD - High Voltage Disconnect (both solar and load).
Hot - High Temperature Disconnect (both solar and load)
OCP - Overcurrent and short circuit protection (load, solar
over-current) short circuit protection (solar only)
0.0 - Short circuit protection (solar only)
5.4 SELF-DIAGNOSTICS (Self-test)
If the push-button is held down for 4 seconds, the ProStar
will go into automatic self-diagnostics.
Note that the button must be released to start the self-test.
NOTE: The push-button can be used to toggle through
the displays faster. The entire self-test takes 30
to 45 seconds. The load will be turned on for 0.1
second and may flash during the test. A short
or overload condition could cause a controller
re-start.
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The following displays will occur (examples are used):
8.8.8
Self-test started, checking the digital meter
segments
12u
The system voltage (12/24/48)
15A
ProStar current rating
r
1.5
Software version installed
E04
A fault has been detected (see list below)
---
Display if no fault is found
25c
Temperature measured at the controller
rP
Remote temp probe is detected (if connected)
25c
Temperature at the remote probe (if connected)
SEn
Battery sense detected (if connected)
S-1
Battery select position (1, 2, or 3)
J-1
Telecom noise jumper cut (change to on-off
regulation)
End
End of the self-test
End---End
Display continue if no error was detected.
End End Display continues if an error has been
detected.
To terminate the self-test, push the button. The self-test can
be repeated to confirm the result.
Error list:
E01
Rotary switch battery selection failure
E03
Voltage reference test failed (circuit, malfunctions)
E04
Solar array current fault (circuit, FETs)
E07
Load FETs off test (load connection, FETs shorted)
E08
Load current fault (circuit, FETs)
E09
Load FETs on test (load circuit, FETs open)
E10
Internal temp sensor out of range high
E11
Internal temp sensor out of range low
E12
Remote temp probe out of range
E13
Battery sense fault (battery V drop over 5V, no
Sense negative connection)
NOTE: In addition to the self-test, observe the solar
and load
currents displayed in the meter. The self-
diagnostics plus the
currents displayed in the meter
will provide a comprehensive test of the
ProStar. Some
faults may not be detected by the
self-test, but the
large majority of potential faults will be tested and
reported in this self-diagnostic test.
Refer to section 9.0 for more
information.
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6.0 INSTALLATION INSTRUCTIONS
The ProStar is installed in 10 steps. Follow the
procedure in section 6.2 for a proper installation and
best performance.
6.1 GENERAL INSTALLATION NOTES
• The ProStar uses stainless steel fasteners, an anodized
heat sink, and conformal coating to protect from harsh
conditions. However, for acceptable service life extreme
temperatures and marine environments should be
avoided.
• The ProStar prevents reverse current leakage at night, so
a blocking diode is not required in the system.
• The ProStar is designed to regulate ONLY solar
(photovoltaic) power. Do not connect it to any other type
of power generator. Do not attempt to regulate a wind
turbine. However, other power sources can be connected
directly to the battery.
• The connector terminals will accept a maximum wire
size of AWG #6 / 16 mm2 (solid/multistrand) or AWG
#8 / 10 mm2 (fine strand). Use a flathead insulated
screwdriver, and torque tightly up to 35 in-lb.
• Stranded wires to be connected to the ProStar
terminals should be prepared first with e.g. clamped
copper heads, etc. to avoid the possibility of one
conductor free out of the connection screw, and possible
contact with the metal enclosure.
• Solar and Battery fuses or DC disconnects are not part of
the ProStar controller.
WARNING: Solar and battery fuses or DC break -
ers are required in the system. These protection
devices are external to the Prostar PWM controller, and must
be a maximum of 18 amps for the PS-PWM-15/M and 37.5
amps for the PS-PWM-30/M.
AVERTISSEMENT: Solaire et batterie fusibles ou
disjoncteurs DC sont nécessaires dans le système.
Ces dispositifs de protection sont externes au contrôleur
PS-PWM et doivent être un maximum de 18 ampères pour
le PS-PWM-25/M et 37.5 ampères pour le PS-PWM-40/M.
WARNING: Installation must comply with all
NEC requirments. All breakers must be properly
rated for wire ampacity, which may require less than the
maximum breaker sizes referenced above.
AVERTISSEMENT: Installation doit être conforme
à toutes les requirments NEC. Tous les disjonc-
teurs doivent être correctement classifiés pour fil courant
admissible, susceptible d’exiger moins que les tailles
maximales disjoncteur référencés ci-dessus.
WARNING: Minimum over-current protection
device interrupt ratings must be 2000A for 12V
systems, and 4000A for 24V systems.
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.
NOTE:
Carefully observe the LEDs at each connection. The
LEDs will indicate proper polarity and a good connection.
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6.2 INSTALLATION STEPS
Refer to the wiring connection diagram in section 3.0.
STEP 1: Mounting
Inspect the controller for shipping damage. Mount the
ProStar to a vertical surface (4 stainless steel #8 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.
NOTE:
Heat sink must be in a vertical position (fins up and
down).
Allow at least 15 cm (6 inches) space above and below the
controller for air flow. Install in an area protected from direct
rain and direct sun. If the controller is installed in an enclo-
sure, some ventilation is recommended. Do not locate in an
enclosure where battery gases can accumulate.
STEP 2: Ratings
Confirm that the solar array and loads will not exceed the
current rating of the ProStar version being installed.
Multiple ProStar units can be paralleled at the system
battery to increase the solar capacity, but do not parallel
loa
ds.
NOTE: The battery should be connected first. This will
activate the controller protection features, and will power
the LEDs to guide installation and start-up.
STEP 3: Battery Connection
Before connecting the battery, measure the battery’s
open-circuit voltage. It must be over 8 Volts to operate the
controller. For 24 volt systems, the battery must be over
15.5 Volts or the ProStar will regulate for 12V. The 12/24V
auto selection is only done at start-up.
Connect the battery and confirm that the 3 Battery Status
LEDs blink in sequence. If they do not light, check the
battery polarity (+/–) and battery voltage.
CAUTION:
The ProStar is protected against
all faults EXCEPT a reversed battery connection
together with a polarized or short circuited load. CONFIRM
that the battery + and – wires are correctly connected before
proceeding. Check the wires and the LEDs.
PRUDENCE: Le ProStar est protégé contre al
défauts SAUF un inversé connexion de la batterie
avec une charge de court-circuit courte ou polarisée.
CONFIRMER que le batterie + et – fils sont connecté
correctement avant de continuer. Vérifiez les câbles et les
del.
The green, yellow or red LED will light depending on the
battery charge state. Confirm one of these LEDs is on
before going to the next step.
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STEP 4: Battery Sense Cables
Battery sense connections are recommended if the
controller is more than 5 meters from the battery. The
Sense Wires, when connected directly to the battery, will
improve the battery charging and control.
Both Sense wires (+/–) must be connected. A small wire size
(18 AWG or larger) can be used for the Sense because the
current is very low. Note that the middle 2 terminals are for
sense (with the smaller wire slots in the case).
NOTE:
If the Battery input voltage is more than 5 Volts
different than the Sense due to voltage drops or faulty
connections, the Sense input will not be recognized by the
ProStar.
STEP 5: Solar Connection
These terminals are used to connect the Solar (PV) array.
First confirm that the solar modules are wired for the same
voltage as the battery.
Use caution, since the solar array will produce power when-
ever in sunlight. If the solar is connected while in sunlight,
the Charging LED indicator will light. Confirm proper
connection with the Charging LED.
STEP 6: Load Connection
CAUTION: Equipment Damage
Do not wire any AC inverter to the load terminals of the
ProStar. Damage to the load control circuit may result.
An inverter should be wired to the battery. If there is a possibility
that any other load will sometimes exceed the Prostar’s maximum
voltage or current limits, the device should be wired directly to
the battery or battery bank. If load control is required, contact
Morningstar Tech Support for assistance.
PRUDENCE : Dommages matériels
Ne pas raccorder n’importe quel convertisseur aux bornes
de la ProStar. Pourrait endommager le circuit de com-
mande de charge. S’il y a une possibilité que n’importe quelle autre
charge dépassera parfois la tension maximale de la Prostar ou limites
de courant, l’appareil doit être câblé directement sur la batterie ou
la batterie. Si le régulateur de charge est nécessaire, contacter le
Support technique de Morningstar d’assistance.
Load terminals are provided to connect lights, DC appliances
and other devices directly to the controller.
Turn the load off,
and connect the load wires to the Load terminals. 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/G – Y)
• the load is not connected, not working, or turned off
Confirm the load is working properly before going to
Step 7.
STEP 7: Battery Type Selection
Using a small screwdriver, turn the rotary switch to select
the Battery Type. There are 3 choices (see section 8.2):
1 = Gel battery
2 = Sealed battery
3 = Flooded battery
A proper selection will flash the 3 Status LEDs together: 1
time for Gel, 2 times for Sealed, and 3 times for Flooded.
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If the rotary switch does not make a good contact with one
of the three selections, the three LEDs will start flashing
together and continue until a good contact is made.
STEP 8: Confirm Installation
After the connections are completed, observe the LEDs
to make sure the controller is operating normally for
system conditions. If the optional digital meter is provided,
observe that the display is scrolling with proper voltage and
amperage values. A self- test can be performed with the
digital meter (see section 5.4).
STEP 9: Grounding
For safety and effective lightning protection, the negative
conductor of the solar system should be properly grounded
(see the NOTE below). In addition, the heat sink can be
grounded with a #8-32 UNC or M4 screw (0.136 hole
provided).
The Solar, Battery, and Load negative terminals are
all connected together inside the ProStar per UL
recommendations. No switching or measurement is done in
the negative current path.
NOTE: For positive ground versions, the Solar, Battery
and Load POSITIVE terminals are connected together
inside the ProStar. The positive system conductor must be
properly grounded. Make sure the upper label of the ProStar
indicates “Positive Ground“ above the version number to
confirm this is a positive ground ProStar controller.
7.0 OPERATION
7.1 OPERATOR’S TASKS
The ProStar is a fully automatic solar system control-
ler that includes many electronic functions to protect
both the controller and the solar system. Battery
charging is also fully automated (see section 8.0).
The only manual tasks performed by the operator are:
a. Installation (see section 6.2)
b. Battery type selection (see section 6.2, Step 7)
c. Disconnect button / Self-test (see section 5.2 and
5.4)
d. Reset if a load short circuit does not automatically
clear (see section 7.3)
e. Maintenance (see section 7.4)
7.2 OPERATIONS & FUNCTIONS
The solar system operator should become familiar with
the following operating functions of the ProStar controller.
Refer to the Technical Specifications (section 10.0) for actual
setpoints and other parameter values.
• 100% Solid State: All power switching is done with FETs.
No mechanical relays are used in the controller.
• Battery Charge Regulation: The ProStar is a PWM bat-
tery charger. See the next section (8.0) for a description of
battery charging.
• Low Voltage Load Disconnect (LVD): An automatic load
disconnect protects the battery from deep discharge.
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The load automatically reconnects when the battery
recovers. A 4-minute delay prevents false LVD disconnects.
• Low Voltage Warning: The red status LED will blink at
low battery capacity to warn of a possible LVD.
• Parallel Controllers: ProStar controllers work very well in
parallel configurations. No blocking diodes are required.
Each controller must have an independent and sepa-
rate solar subarray and a load that does not exceed the
controller’s rating.
• Auxiliary Generators: Engine generators and other
sources of power may be connected directly to the battery
for charging. It is not necessary to disconnect the ProStar
from the battery. However, do not use the ProStar to
regulate these other sources of power.
Noise:
The ProStar circuit minimizes switching noise and
filters noise output. A properly grounded system will also
minimize noise. If noise is present in a telecom or radio
load, refer to section 7.5 below.
7.3 PROTECTIONS
The ProStar is fully protected against system faults listed be-
low. Recovery is automatic except where noted below. Refer
to sections 4.0 and 5.0 for fault indications.
• Solar short circuit and overload – fully automatic recovery
• Load short circuit and overload – after 3 automatic load
reconnect attempts (10 seconds between each attempt),
the fault must be cleared and the load must be turned off or
disconnected for 10 seconds or longer to restore power to
the load terminals.
• Reverse polarity – fully protected except per Caution
below
• Battery disconnected – the load is protected from voltage
spikes
• High temperature – first the solar is disconnected, then
the load will be disconnected; auto reconnects
• High battery voltage – first the solar is disconnected, then
the load will be disconnected; auto reconnects
• Very low battery voltage – brown-out protection, auto
recovery into LVD state
• Battery select error – defaults to gel battery setting,
flashes LEDs
• Temperature sensor failure – a remote probe failure de-
faults to the internal temperature sensor, which defaults to a
fixed 25°C if it fails.
CAUTION: The ProStar is protected against
all faults EXCEPT a reversed battery connection
together with a polarized or short circuited load. CONFIRM
that the battery + and – wires are correctly connected before
proceeding. Check the wires and the LEDs.
PRUDENCE: Le ProStar est protégé contre al
défauts SAUF un inversé connexion de la bat-
terie avec une charge de court-circuit courte ou polarisée.
CONFIRMER que le batterie + et – fils sont connecté
correctement avant de continuer. Vérifiez les câbles et les
del.
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7.4 INSPECTION & MAINTENANCE
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.
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. SOUS CERTAINES
CONDITIONS DE DÉFAILLANCE, LA BATTERIE POUR-
RAIT DEVENIR TROP CHARGÉE. TEST ENTRE TOUTES LES
BORNES ET LA MASSE AVANT DE TOUCHER.
The following inspections and maintenance tasks are rec-
ommended at least two times per year for best controller
performance.
1. Confirm that the correct battery type is selected. Turn the
rotary switch to another setting and then back to the setting
desired, and count the LED flashes.
2. Confirm that the maximum current of the solar array and
load does not exceed the ProStar ratings.
3. Tighten all the terminals. Inspect for loose or broken wire
connections.
4. Check that the controller is securely mounted in a clean,
protected environment.
5. Check that the air flow and the ventilation holes are not
blocked.
6. Inspect for dirt, insects, nests, and corrosion.
7. Check that the controller functions and LED indicators are
correct for the system conditions at that time.
7.5 TELECOM NOISE JUMPER
Some telecom equipment will produce noise when
the ProStar begins PWM regulation. If this occurs, a
jumper can be cut to eliminate the noise. Instructions
follow:
• First, try to improve the system grounding which
often eliminates the noise. The PWM battery charging
provides a significant benefit to the battery, and it is
worth trying to preserve the PWM charging.
• If the noise continues, disconnect the controller and
remove the ProStar assembly from its plastic case.
• Locate a vertical resistor in the upper right hand
corner of the board, near the microcontroller. This is
identified as “J11“ on the board.
• Cut one leg of the resistor and separate the leads.
This will convert the battery charging to a typical
“on-off“ regulation of the solar energy. The switching
is very slow, so the noise will not be noticeable. The
equalization and float features of the battery charging
algorithm are preserved in the “on-off“ mode.
In the future, this can be reversed back to PWM if the
cut jumper leg is soldered back together.
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8.0 BATTERY CHARGING INFORMATION
The ProStar is an advanced, fully automatic solar battery
charger. No adjustments are required except to select the
battery type at installation (see section 8.2 below).
NIGHT
NIGHT
BULK
CHARGE
ABSORPTION
FLOAT
EQUALIZE
VOLTAGE
TIME
8.1 PROSTAR CHARGING METHOD
The ProStar uses 4 stages of charging for rapid, efficient
and safe battery charging. These are shown in the diagram
above:
1. Recharging with 100% of available solar energy.
2. PWM constant-voltage regulation to prevent heating
and excessive battery gassing. Pulse charging to restore full
battery capacity.
3. Float: After battery is fully recharged, ProStar reduces to
a float or trickle charge. The transition depends on battery
history. A load that exceeds available solar output will return
ProStar to the PWM mode.
4. Equalize: A boost charge that depends on elapsed
time and battery history. Flooded cells receive a
vigorous equalization, sealed batteries a smaller boost to
bring uneven cells into balance and extend the battery life.
Gel cells are not equalized.
8.2 SELECT BATTERY TYPE
The Battery Type rotary switch allows selection of 1 of 3
charging algorithms. These are broadly defined as the
following battery types as noted on the lower label:
1. Gel: Some gel and other battery types recommend
lower regulation voltages and no equalization. This setting
regulates to 14.0V (for a 12V battery).
2. Sealed: AGM, “maintenance free“ and some types of gel
batteries. Regulates to 14.15V (12V battery) with 14.35V
boost charging.
3. Flooded: Vented cells that require water to be added.
Regulates to 14.4V with 14.9V and 15.1V equalizations (12V
battery).
The above values are 2 times for 24V, and 4 times for 48V.
The battery type selection can be changed at any time.
8.3 PROSTAR CHARGING FEATURES
Other ProStar capabilities for best battery life follow:
• Night Disconnect: The solar array automatically discon-
nects at night to prevent reverse current leakage from the
battery.
• Battery Sense: Good battery performance requires ac-
curate charging. Voltage drops in the battery power cables
can distort the battery charging. The Sense wires eliminate
the voltage drops for optimized charging.
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• Temperature Compensation: Four control setpoints
(25°C reference) are compensated for temperature (PWM
regulation, float, equalization, high voltage disconnect). The
charging is compensated by –5 mV/°C /cell (–30mV/°C for a
12V battery). Compensation is limited to minus 30°C.
• Battery Equalization:
Calendar – 25 days Sealed Flooded
Equalization voltage 14.3 14.9
Cumulative time 1 hour 1 hour
Time starts above (V) 14.3 14.6
Battery History (flooded only)
Battery voltage falls below (V) N/A 11.7
Equalize voltage 15.1
Cumulative time 2 hours
Time starts above (V) 14.6
Reset 25-day calendar yes
NOTE:
Multiply the preceding battery set-points by two for
24V systems.
9.0 TESTING and TROUBLESHOOTING
9.1 SELF-DIAGNOSTICS
If your ProStar includes the optional digital meter, refer to
section 5.4 for how to perform a self-test of the ProStar.
This will test for almost all failure modes of the ProStar and
display any faults that are found.
If the self-diagnostic test indicates that no failures were
found, it is very likely that the problem is with the solar
system or battery.
9.2 TECHNICAL SUPPORT
Additional technical information and support can be found
at Morningstar’s Website:
www.morningstarcorp.com
9.3 TESTING WITH A POWER SUPPLY
The ProStar can be tested with a power supply used in place
of either the solar array input or the battery. To avoid dam-
age to the ProStar, observe the following cautions:
• Current limit the power supply to no more than half the
ProStar rating.
• Set the power supply to 15 Volts DC or less for 12V sys-
tems (30V for 24V systems and 60V for 48V systems).
• Connect only one power sup
ply to the controller.
Failure to follow these precautions may void the
warranty.
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