Morningstar ProStar-15 User manual

SOLAR CONTROLLERS
OPERATOR’SMANUAL
PROSTARTAR -12
PROSTAR VERSIONS INCLUDED IN THIS MANUAL
PS-15 PS-30 PS-15M-48V
Rated Solar Current 15A 30A 15A
Rated Load Current 15A 30A 15A
System Voltage 12/24V 12/24V 48V
Digital Meter Option yes yes standard
Positive Ground Option no yes yes
PROSTAR VERSIONS INCLUDED IN THIS MANUAL
1098 Washington Crossing Road
Washington Crossing, PA 18977 USA
phone: [phone]
fax: [phone]
email: [email protected]

5.37
(136)
6.01
(153)
4.14
(105)
3.50
(89)
inches (mm)
2.17
(55)
.18
(4.57)
PROSTAR DIMENSIONS

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CONTENTS
1.0 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.0 IMPORTANT SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
3.0 QUICK START INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.0 LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.0 DIGITAL METER & MANUAL DISCONNECT . . . . . . . . . . . . . . . . 6
5.1 Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 Manual Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.3 Display Disconnects & Protections . . . . . . . . . . . . . . . . . . . . . 6
5.4 Self-Diagnostics (Self-Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.0 INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 General Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2 Installation Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.0 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.1 Operator’s Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.2 Operations & Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.3 Protections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.4 Inspection & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.5 Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8.0 BATTERY CHARGING INFORMATION . . . . . . . . . . . . . . . . . . . . . 13
8.1 ProStar Charging Method. . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.2 Select Battery Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.3 ProStar Charging Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9.0 TESTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 14
9.1 Self-Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9.2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9.3 Testing with a Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.0 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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1.0 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.
2.0 IMPORTANT SAFETY INFORMATION
”Always Put Safety First“
• Be very careful when working with batteries. Wear eye protection. Have fresh water
available to wash and clean any contact with battery acid.
• Charge only lead-acid batteries that are properly sized for the system.
• Explosive battery gasses can be present during charging. Be certain there is enough
ventilation to release the gasses.
• Use insulated tools and avoid metal objects near the batteries.
• Carefully read the battery manuals and other equipment manuals before installing
the solar system. Observe ALL precautions when working with batteries and power
electronics.
• Fuses or DC disconnects may be required in the system. These protective devices
are not part of the ProStar controller.
• Avoid large voltage drops in the battery wires. Use the Battery Sense connection for
best battery charging and system performance.
• Do not allow water to enter the controller.
• Avoid touching the controller heat sink. Under certain operating conditions, the heat
sink can become hot.
• Install the controller in a vertical position with adequate space for ventilation.
• Ensure that the system is properly grounded.
• SAVE these instructions for future reference.
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.
1. 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.
2. Make sure the Solar and Load currents will not exceed the ratings of the ProStar
version being installed.

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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.
5. Connect the Solar. With sunlight, the green Charging LED will light.
6. 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 confirm normal operation.
10. It is recommended that the system be properly grounded.
4.0 LED INDICATORS
The 4 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 a low voltage load disconnect
(LVD) warning
ON indicates the load has been disconnected (LVD)
SENSE
+––
+
–+
BATTERY LOAD
PV
+–
+–
1
UP
TEMP. SENSORCHARGING BATTERY STATUS
BLINK: LOW
ON: LVD
4
2
3
1
BATTERY
TYPE
1– GEL
2– SEALED
3– FLOODED
3
10
6
5
BATTERY
579


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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
5.0 DIGITAL METER & MANUAL DISCONNECT
A digital meter is available with the ProStar controller as an option. If your version includes the
meter display, this section 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 meter 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, however,
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 conditions will be displayed in the digital
meter when they occur:
LUD LVD – low voltage load disconnect (load only)
HUD high voltage disconnect (both solar and load)
HOT high temperature disconnect (both solar and load)
OCP overcurrent and short circuit protection (load, solar overcurrent)
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.

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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 restart.
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
R1.5 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 continues 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:
E0 I 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)
E I0 Internal temp sensor out of range high
E I I Internal temp sensor out of range low
E I2 Remote temp probe out of range
E I3 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 exist
that are not 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.
• Fuses or DC disconnects may be required in the system. These protection devices
are not part of the ProStar controller.
NOTE: Carefully observe the LEDs at each connection. The LEDs will indicate
proper polarity and a good connection.
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 enclosure, some ventilation is recommended.
Do not locate in an enclosure where battery gasses 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 loads.

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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
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. CON-
FIRM that the battery + and – wires are correctly connected before
proceeding. Check the wires and the LEDs.
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.
STEP 4: Sense
Battery sense connections are recommended if the controller is more than 5 meters
from the battery. The Sense, 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
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 whenever 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
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.

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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.
If the rotary switch does not make a good contact with one of the 3 selections, the
3 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 controller 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)