Morningstar PROSTAR-12 User manual

PHOTOVOLTAIC SYSTEM CONTROLLERS
O PERATOR ’ S M ANUAL
P
RORO
S
TARTAR
MODEL RATINGS
P
RO S TAR -12 P RO S TAR -20 P RO S TAR -30
Rated PV current 12A 20A 30A
Rated Load current 8A 16A 30A
System voltage: 12 and 24 volts, auto selected
ProStar models • Standard
included in this • With LCD meter
manual:

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CONTENTS
1.0 G
ENERAL I NFORMATION .................................................... 2
2.0 Q UICK S TART I NSTRUCTIONS ............................................ 3
3.0 I NDICATORS ...................................................................... 4
3.1 LED Indicators .................................................. 4
3.2 Digital Meter & Disconnect.............................. 5
4.0 I NSTALLATION I NSTRUCTIONS ............................................ 6
4.1 Polarity Protection ............................................ 6
4.2 Installation Procedure ...................................... 7
5.0 O PERATION ........................................................................ 10
5.1 Controller Operation ........................................ 10
5.2 Controller Functions ........................................ 10
5.3 Inspection and Maintenance ............................ 11
5.4 Troubleshooting................................................ 12
6.0 S PECIFICATIONS ................................................................ 15
1.0 GENERAL INFORMATION
Thank you for selecting the ProStar PV controller. The
ProStar is a highly sophisticated controller using advanced
technology and microprocessor control. The battery charg-
ing process has been 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 con-
troller. This will help you to make full use of the many
advantages the ProStar can provide to your PV system.
PRECAUTIONS “Always Put Safety First”
• Always be very careful when working with batteries. Batteries
can produce explosive hydrogen gas. A short-circuit can pull
thousands of amps from the battery.

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•Even though the system is only 12 or 24 volts, both the PV
array and battery can contain lethal amounts of electrical
power.
• Do not splash water on the controller, do not allow water to
enter the ventilation slots.
• Do not touch the heatsink. Under certain operating condi-
tions, the heatsink can become hot.
• Always install the controller in a vertical position. Ensure
adequate space for ventilation, and never block the ventila-
tion slots.
• Do not short-circuit the PV array while connected to the
controller. This will damage the controller.
• Do not exceed the current ratings of the controller.
2.0 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.
1. Mount the ProStar to a vertical surface. Allow space above
and below the controller for air flow. The heatsink MUST be
in a vertical (up & down) position.
2. Make sure the PV and load currents will not exceed the
ratings of the ProStar model being installed.

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3. Connect the BATTERY first. Observe that all LED’s flash in
sequence one time.
4. Connect battery SENSE leads (if utilized). This is recom-
mended if the controller is placed more than 2 to 3 meters
from the battery.
5. Connect the PV (solar array). With sunlight, the green
CHARGING LED will light in 2 minutes.
6. Connect the LOAD . If the LED indicators begin to flash, the
load is shorted. Refer to the detailed installation instructions.
7. The BATTERY TYPE at start-up is sealed (LED on). If the PV
system battery is a flooded type, use a piece of wire to touch
the SELECT PIN to the battery minus terminal to change to
flooded (LED goes off). This must be reset every time the
battery is disconnected.
8. The ProStar will automatically select for a 12 or 24 volt sys-
tem. If this is a 24 volt system, first check to confirm that the
battery is above 17 volts, and boost-charge the battery if
under 17 volts.
9. Observe the LED indicators. After a few minutes to clear
delays and resets, the LED’s should operate per system con-
ditions as described in the following chart (section 3.1).
10. For effective surge protection, it is recommended that the
negative system conductor be properly grounded.
3.0 INDICATORS
3.1 LED I
NDICATORS
The ProStar utilizes 5 LED (light emitting diode) indicators
to provide controller and system status information. These
are described in the following table.
I NDICATOR C OLOR D ESCRIPTION
BATTERY TYPE Green ON: Sealed battery type
OFF: Flooded battery type
STATUS Green ON: PV array power available
and charging battery
OFF: PV array power is off

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BATTERY CHARGE Green ON: Battery near full charge
BATTERY CHARGE Yellow ON: Battery at middle capacity
(about 35% to 80% SOC)
NOTE: does not indicate
a problem
BATTERY CHARGE Red FLASH: Battery at low charge,
warning
ON: Load has been disconnected
All LED’s SEQUENTIAL FLASH:
Load is short-circuited
High temperature shutdown
High voltage disconnect
Initial battery connection (startup)
(flashes one cycle only)
3.2 D IGITAL M ETER & M ANUAL D ISCONNECT
If your model is supplied with the LCD meter, the controller
will include a precision 3-digit meter that displays battery
voltage, PV array current and load current. The meter will
automatically sequence between these 3 parameters. The
3 small green status LED’s will indicate which parameter is
being displayed.
The LCD meter will operate from -30°C to +85°C. The
values displayed are accurate to within a few percent.
However, please note that if the
BATTERY SENSE is not
connected, the voltage displayed will be reduced by the
voltage drops in the battery wires.
The red
DISCONNECT button will provide an immediate
disconnect of both the PV array and load when pushed
(the button’s red LED turns on). To return the controller to
normal operation, push the button a second time. Note
that restarting the controller with the button will cause the
controller to go through the start-up sequence with the
normal delays and LED indications.

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4.0 INSTALLATION INSTRUCTIONS
4.1 P
OLARITY P ROTECTION ( AND LED I NDICATIONS )
CAUTION:Although the ProStar is fully protected from
reversed polarity, the system operator and other
equipment may be at risk when polarities are
reversed. Carefully check each connection and
observe the LED’s to make sure polarity is correct.
CONNECTION POLARITY RESULT AND LED INDICATION
Battery Correct All 5 LED’s will sequence one time.
BATTERY TYPE indicator will remain on
(default is sealed). The green BATTERY
CHARGE indicator will light within 15 sec-
onds, and will then cycle to the correct state.
Battery Reversed No LED’s will light. No damage will occur.
Sense Correct No additional indications.
Sense Reversed If the battery has been connected cor-
rectly, there will be sparking at the termi-
nals. If the negative sense lead is con-
nected first, no damage will occur (small
possibility of damage if positive connect-
ed first). There will be no indications.
PV Array Correct LED’s will light only if the battery has
been connected. During daytime with
battery present, the CHARGING indica-
tor will light after a 2 minute delay.
PV Array Reversed No damage will occur. The CHARGING
indicator will not light after the 2 minute
delay.
Load N/A If a load short-circuit exists, load will
instantly disconnect to protect the
controller. LED’s will then sequence
to indicate a short.

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4.2 I NSTALLATION P ROCEDURE
GENERAL INSTALLATION NOTES:
•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 PV power. Do
NOT connect to any other type of power generator.
• The ProStar automatically selects 12 or 24 volt setpoints at
battery connection. Do not connect a battery larger than 24
vdc (12 cells) or the controller will be damaged.
• The connector terminals will accept a maximum wire size
of AWG #6 (solid/multistrand) or AWG #8 (fine strand) or a
maximum wire diameter of 5.0 mm. Use a flathead insulated
screwdriver (up to 5 mm).
NOTE:Carefully observe the LED indications at each con-
nection. Per the chart above, the LED’s will indicate
proper polarity and a good connection.
NOTE:Connections may be made in any order. However,
the BATTERY must be connected first for the LED
indicators to operate. The SENSE input will not
power the LED’s.
INSTALLATION STEPS:
1. Inspect the controller for shipping damage. Mount the
ProStar to a vertical surface (4 stainless steel #8 self-tapping
screws are included). Do not install directly over an easily
combustible surface since the heatsink may get hot under
certain operating conditions.
NOTE:Heatsink must be in a vertical (up and down) position.
Allow a minimum of 15 cm (6 inches) space above and below
the controller for air flow. Install in an area protected from
direct rain and extreme temperatures.
If the controller is installed in an enclosure, some ventilation
is recommended. If installed in a sealed enclosure, under
extreme conditions the ProStar may, at times, reach 70ºC
and disconnect the PV array briefly.
2. Confirm that the PV array and loads will not exceed the cur-
rent ratings of the ProStar model being installed (see chart
on front cover).

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Multiple ProStar units can be paralleled at the system battery,
but be careful that no PV sub-array exceeds a controller’s
individual current rating.
3. BATTERY (+ and -) Before connecting the battery, check the
open-circuit voltage of the system battery. It must be at least
8 volts for the controller to operate. If your PV system is 24
volts, the battery MUST be over 17 volts, or the controller
will regulate at the 12 volt setpoints. Any battery starting at
less than 11 (or 22) volts should be fully charged before con-
nection to a PV system, or battery life will be significantly
reduced.
NOTE: The battery should be connected first. This will
activate the controller self-protection features,
and will power the LED’s to guide installation
and start-up.
Connect the battery and observe that all 5 LED’s flash in se-
quence one time. If the LED indicators do not sequence or
the BATTERY TYPE LED does not light, check the battery
polarity.
The green, yellow or red BATTERY CHARGE LED will light
depending on the battery charge state.
4. SENSE (+ and -) Battery sense leads are recommended if the
controller is located more than 2 or 3 meters from the bat-
tery. This will avoid voltage drops and improve the control
accuracy. However, if the sense leads are not connected, the
controller will default to BATTERY connections for control.
A smaller wire size can be used for sense (draws less than 1
mA current). Note that the wire entry slots into the case for
SENSE are smaller than the other system power terminals to
prevent mixing the BATTERY and SENSE connections.
5. PV (+ and -) Use these terminals to connect the solar array.
First confirm that the PV modules are wired for the same
voltage as the battery (either 12 or 24 volts).
Use caution, since the PV array will generate power whenever
in sunlight. Also, be careful not to short-circuit the PV array
while connected to the controller, since this will damage the
controller.
There is a 2 minute delay after connection of the PV array
before the controller begins charging. Check that the

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CHARGING indicator comes on after 2 minutes to confirm
that the PV array has been properly connected.
6. LOAD (+ and -) Turn the load off. Connect the load to
LOAD terminals, and then turn the load on. If the battery is
below the load disconnect voltage, the load will be discon-
nected (normal LVD). There may be a short delay.
If the load is short-circuited, the controller will instantly
disconnect the load and flash the LED’s in sequence. If this
occurs, remove the load and repair the short. It will then be
necessary to disconnect the BATTERY + wire and reconnect
the battery to reset the ProStar for normal operation (or press
the red DISCONNECT button twice if the LCD meter option
is supplied).
7. The BATTERY TYPE defaults to sealed, and the green LED
should be on. If your battery is a flooded type, use a piece of
wire to touch the SELECT PIN to the BATTERY - (negative)
terminal or to the negative battery post. This will change the
battery charging setpoints from a sealed to a flooded battery.
When the change has been made, the green BATTERY TYPE
LED will turn off.
Check the LED to confirm the change. This SELECT PIN can
be used repeatedly. No damage can occur from touching the
pin to other terminals or parts of the controller. The BAT-
TERY TYPE can be changed between sealed and flooded
any number of times.
NOTE:Remember that flooded batteries must be selected
every time the battery is disconnected, because the
controller will default to sealed at start-up.
Confirm that the proper battery type has been selected by
checking the green LED. No other control setpoints can be
adjusted since they have been factory set for optimum per-
formance.
8. After about 5 minutes, observe all the LED’s. Use the LED
indicator chart in section 3.1 to make sure the controller is
operating normally for system conditions.
9. For safety and effective lightning protection, the negative
conductor of the PV system should be properly grounded.
The ProStar connects the PV-negative, Battery-negative and
Load-negative internally per UL recommendations. No
switching is done in the negative current path.

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5.0 OPERATION
5.1 C
ONTROLLER O PERATION
The ProStar is a fully automatic PV system controller that
includes many electronic functions to protect both the con-
troller and the PV system. Battery charging is managed by a
constant-voltage, PWM algorithm that has been optimized
for PV systems.
The only manual tasks performed by the operator are:
a. Installation (see section 4.0)
b. Battery type selection (see section 4.2-7)
c. Disconnect button (with LCD meter, see section 3.2)
d. Reset if load short-circuits (see section 4.2-6)
e. Maintenance (see sections 5.3 and 5.4)
5.2 C ONTROLLER F UNCTIONS
The PV system operator should become familiar with
the following functions of the ProStar controller. Refer to
Technical Specifications (6.0) for actual setpoints and other
parameter values.
LVD - Low Voltage Automatic load disconnect to protect battery
Load Disconnect from deep discharge. Auto reconnect.
Current compensated for high load currents.
Low Voltage Alarm Red LED flashes at low battery capacity to
warn of possible LVD if discharging continues.
Over Voltage If battery voltage rises above the constant
Protection voltage regulation setpoint, the PV array is
disconnected. Auto reconnect.
HVD - High Voltage Both PV array and load are disconnected
Disconnect when battery rises to dangerous voltage.
The LED’s flash in sequence. Auto reconnect
as voltage falls.