Morningstar ProStar PS-15 User manual

Solar Charging System Controller
Installation, Operation, and Maintenance Manual
www.morningstarcorp.com
ProStar TM
MODELS
PS-15
PS-30
PS-15M
PS-30M
For the most recent manual revision, see the
version at: www.morningstarcorp.com

ProStar Operator’s Manual iii
TABLE OF CONTENTS
DIMENSIONS [inches (millimeters)]
1.0 Important Safety Instructions ........................ 1
2.0 General Information ..................................... 13
2.1 Overview ......................................................... 13
2.2 Regulatory Information ............................... 14
2.3 Features ...........................................................16
2.4 Optional Accessories ......................................18
3.0 Installation ..................................................... 21
3.1 General Installation Notes
............................ 21
3.2 Configuration ........................................... 23
3.3 Mounting
................................................. 26
3.4 Wiring ...................................................... 28
4.0 Operation.................................................41
4.1 Battery Charging Information.....................41
4.2 Load Control Information...................................54
4.3 LED Indications.................................................. 56
4.3.1 Power-up............................................................ 56
4.3.2 Status LED..........................................................56
4.3.3 State-of-charge LEDs......................................... 57
4.4 Push-button Use in Non-Metered Versions......58
4.5 Custom Settings........ ...................................... 59
4.5.1 Programming with Meter Display..................... 59
4.5.2 Programming in MSView...................................61
Continued
SPECIFICATION SUMMARY
PS-15 / PS-15M PS-30 / PS-30M
Nominal Battery voltage 12 or 24V 12 or 24V
Max. PV Open- Circuit
Voltage* 30 or 60V 30 or 60V
Max. Battery Charging Current 15A 30A
Rated Load Current 15A 30A
*Array voltage should never exceed this limit

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iv ProStar Operator’s ManualImportant Safety Instructions
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TABLE OF CONTENTS (Cont.)
4.5.3 Meter Display Operation...................................61
4.5.3.1 Directional Key Use and Operation /
Navigating the Meter Map........................... 61
4.5.3.2 Adjusting the Meter Display..........................62
4.5.4 Using the Meter Display to Program Charging
Set-points, Load Control, Communications,
and Advanced Settings.................................62
4.5.5 Lighting Control - Programming Oveview........62
4.5.6 Lighting Programming Using Meter Display.... 63
4.5.7 Low Temperature Foldback..............................64
4.6 Inspection and Maintenance............................ 65
5.0 Troubleshooting............................................. 67
5.1 Alarms...............................................................67
5.2 LED Fault Indications........................................68
5.3 Battery Charging and Performance Issues.......73
6.0 Warranty and Policies................................... 75
7.0 Technical Specifications................................ 79
Appendix A - De-rating...........................................83
Appendix B - Wire Sizing....................................... 84
Appendix C - Certifications.....................................85
SAVE THESE INSTRUCTIONS.
This manual contains important safety, installation,
operating and maintenance instructions for the ProStar
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.
Les symboles suivants sont utilisés dans ce manuel pour
indiquer des conditions potentiellement dangereuses ou
1.0 IMPORTANT SAFETY INSTRUCTIONS

3
2ProStar Operator’s ManualImportant Safety Instructions
1.0
WARNING: THE COMMUNICATIONS
PORT IS CONSIDERED TO BE DVC B. AN
EXTERNAL ISOLATOR IS REQUIRED IF IT IS
TO BE CONNECTED TO A DVC A CIRCUIT.
• 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 TENSION DANGEREUSE SOLAIRE. SOUS
CERTAINES CONDITIONS DE DÉFAILLANCE, LA BAT-
TERIE POURRAIT DEVENIR TROP CHARGÉE. TEST
ENTRE TOUTES LES BORNES ET LA MASSE AVANT
DE TOUCHER.
AVERTISSEMENT: LE PORT DE
COMMUNICATION EST CONSIDÉRÉE
COMME DVC B. UN ISOLATEUR EXTERNE
N'EST NÉCES SAIRE SI C'EST D'ÊTRE CONNECTÉ À
des consignes importantes de sécurité.
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.

5
4ProStar Operator’s ManualImportant Safety Instructions
1.0
UN DVC UN CIRCUIT.
• External solaire et la batterie se déconnecte sont
nécessaires.
• Déconnectez toutes les sources d’alimentation du
contrôleur avant d’installer ou de régler le ProStar.
• Le ProStar MPPT ne contient aucun fusible ou
interrupteur. Ne tentez pas de réparer.
• Installez des fusibles/coupe-circuits externes selon
le besoin.
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 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.
• 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 ex-
cessive heating from a loose connection.
• Use properly sized conductors and circuit
interrupters.
• The grounding terminal is located in the case, 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 controller must be installed by a qualified

7
6ProStar Operator’s ManualImportant Safety Instructions
1.0
technician in accordance with the electrical regulations
of the country of installation.
A means of disconnecting all power supply poles must
be provided. These disconnects must be incorporated
in the fixed wiring.
The ProStar negative power terminals are common,
and must be grounded as instructions, local codes,
and regulations require.
A permanent, reliable earth ground must be estab-
lished with connection to the ProStar ground terminal.
The grounding conductor must be secured against any
accidental detachment.
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 comme
requis par le code local ou les
réglementations
• Montez le ProStar à l’intérieur. Empêchez
l’exposition aux éléments et la pénétration d’eau
dans le contrôleur.
• Installez le MPPT ProStar dans un endroit qui
empêche le contact occasionnel. Le dissipateur de
chaleur ProStar 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 l'affaire
et est identifié par le symbole ci-dessous :
• 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 régulateur MPPT ProStar doit être installé par un
technicien qualifié conformément aux règlements du

9
8ProStar Operator’s ManualImportant Safety Instructions
1.0
pays d'installation électriques.
Un moyen de déconnexion de tous les poteaux
d'alimentation doit être fourni. Ceux-ci se déconnecte
doit être intégrée dans le câblage fixe.
Une mise à la terre permanent et fiable s'impose avec
raccordement à la borne ProStar.
Les bornes de puissance négative ProStar sont
communs et doivent être mise à la terre comme les
directives, les codes locaux, et les règlements exigent.
Le conducteur de terre doit être protégée contre tout
détachement accidentel.
Battery Safety
WARNING: A battery can present a risk
of electrical 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
regulations or codes for requirements.
AVERTISSEMENT : Risque d'Explosion.
Au rebut des piles est nécessaire. Ne
pas jeter les piles dans le feu. Se référer
aux réglementations locales ou des codes pour les
exigences.
CAUTION: When replacing batteries,
use properly specified number, sizes, types,
and ratings based on application and system de-
sign.
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

11
10 ProStar Operator’s ManualImportant Safety Instructions
1.0
• Use tools with insulated handles and avoid placing
tools or metal objects on top of batteries.
• Disconnect charging source prior to connecting or
disconnecting 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 maintenance
(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.
• 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 su-
pervisé, par un personnel bien informé sur les piles
et les précautions de sécurité appropriées.
• Soyez très prudent quand vous travaillez avec des
grandes batteries au plomb. Portez des lunettes de
protection et ayez de l’eau fraîche à disposition en
cas de contact avec l’électrolyte.
• Enlevez les montres, bagues, bijoux et autres ob-
jets 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 télé-
commande n'ayant ne pas un circuit d'alimentation
mise à la terre).

ProStar Operator’s Manual 13
2.0
12 Important Safety Instructions
• Lisez attentivement les instructions du fabricant de
la batterie avant d'installer / connexion à ou retrait
des batteries du ProStar.
• 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
pendant 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 bat-
terie est correct avant de commencer la charge. Ne
tentez pas de charger une batterie gelée.
• Recyclez la batterie quand elle est remplacée.
2.1 Overview
Thank you for choosing the ProStar solar charge
controller.
The ProStar battery charging process has been
optimized for long battery life and improved system
performance. Self-diagnostics and electronic error
protections prevent damage when installation
mistakes or system faults occur. The controller also
features eight (8) adjustable settings switches, a
communication port, and terminals for remote battery
temperature and voltage measurement.
Please take the time to read this operator’s manual
to become familiar the many benefits the ProStar can
provide for your PV systems, for example:
• Rated 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 mm2wire
• Includes battery voltage sense terminals
• Optional remote battery temperature sensor
• 5-year warranty (see Section 6.0)
2.0 GENERAL INFORMATION

General Information ProStar Operator’s Manual 15
14
2.0
2.2 Regulatory Information
NOTE: This section contains
important information on
regulatory requirements.
ProStar controllers comply with the
following European (ENs) standards:
• Immunity: EN 61000-4-3: 2006
EN 61000- 4-6: 2009
• Immunity: EN 61000-6-2: 2005/AC:2005 EMC
• Emissions: EN 61000-6-4: 2007 +A1:2011 EMC
FCC Requirements:
This device complies with Part 15 of the
FCC rules. Operation is subject to the
following two conditions: (1) This device
may not cause harmful interference, and,
(2) this device must accept any interference
received, including interference that may
cause undesired operation.
Changes or modifications not expressly
approved by Morningstar, for compliance,
could void the user’s authority to operate
the equipment.
NOTE: This equipment has been tested
and found to comply with the limits for a
Class B digital device, pursuant to Part 15 of the
FCC
rules. These limits are designed to provide reasonable
protection against harmful interference in a residential
installation. This equipment generates, uses, and can
radiate radio frequency energy and, if not installed and
used in accordance with the instruction manual, may
cause harmful interference to radio communication.
However, there is no guarantee that interference will not
occur in a particular installation. If this equipment does
cause harmful interference to radio or television
reception, which can be determined by turning the
equipment on and off, the user is encouraged to try to
correct the interference by one or more of the following
measures:
• 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.
This Class B digital apparatus complies with Canadian
ICES-003.

General Information ProStar Operator’s Manual 17
16
2.0
Figure 2.1. ProStar Features
Figure 2.3. Removable
Terminal Cover
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.
12
12
12
10
4
2
12
3
1
8
9
5
11
6
7
13
14
15
Figure 2.2. Non-Metered
Unit Push-Button
1 - Charging Status / Error LED
Shows charging current and error condition statuses.
2 - Heatsink
Aluminum heatsink (underneath) to dissipate
controller heat (the ProStar is 100% passively cooled
for reliability)
3 - Meter Display (optional)
Digital LCD monitoring and programming display
4 - Battery Status / Fault LED Indicators
Three state of charge (SOC) LED indicators show
charging status and controller faults
5 - Solar Positive and Negative Terminals
Power connections for Solar (+) and (-) cable
terminations
6 - Battery Positive and Negative Terminals
Power connections for Battery (+) and (-) cable
terminations
7 - Load Positive and Negative Terminals
Power connections for Load (+) and (-) cable
terminations
8 - Local Temperature Sensor
Compensates charging based on ambient
temperature, in absence of Remote Temperature
Sensor
9 - Meter Directional Buttons
Used to navigate throughout the meter map
10 - DIP Switches
Eight (8) settings switches to configure operation of
the ProStar

General Information ProStar Operator’s Manual 19
18
2.0
11 - MeterBusTM Port
RJ-11 socket for Morningstar MeterBusTM network
connections
12 - Battery Sense Terminals
Connection points for battery voltage sensing wires
13 - Remote Temperature Sensor Terminals (RTS)
Connection points for a Morningstar RTS to remotely
monitor battery temperature
14 - Push-button (non-metered version)
Initiates manual Equalization, clears any faults or
reminders, conducts a lighting test, restores settings
to factory default
15 - Removable Terminal Cover
Cover protects circuit board and termination points
2.4 Optional Accessories
The following accessories are available for purchase
separately from your authorized Morningstar dealer:
Remote Temperature Sensor (Model: RTS)
The RTS measures battery temperature for accurate
temperature compensation and is recommended
when the ambient battery temperature differs from the
ambient controller temperature by +/- 5º C or more.
An RTS can be attached to the ProStar at any time.
The ProStar will automatically use the RTS for battery
temperature compensation when installed. The stan-
dard cable length is 33 ft (10m), and can be extended
to 100 ft (30m) if required. Installation instructions are
provided with the RTS.
NOTE: The use of a Remote Temperature
Sensor (RTS) is strongly recommended.
Controller location, air flow, and system power can
drastically affect the local temperature sensor reading.
An RTS will provide optimal charging performance.
RM-1 Meter
A remote meter for monitoring system variables,
for use through the ProStar Meterbus port.
RelayDriver (RD-1)
The Relay DriverTM accessory enables the ProStar
to control external devices. Four (4) relay control
ports can be configured (in various combinations) to
perform the following tasks:
• generator control (2, 3, and 4-wire configurations)
• dry contacts for alarms and other signals
• advanced load control
• vent fan control
• DIN rail compatible or surface mount
For more information on the Relay Driver, visit our
website at www.morningstarcorp.com, or inquire with
your local Morningstar dealer.
Ground-fault Protection Device (GFPD-150V)
The GFPD-150V detects power source ground faults
and interrupts current as required by the US National
Electrical Code.

ProStar Operator’s Manual 21
3.0
General Information
20
Communications Support:
Ethernet MeterBus Converter (EMC-1)
This product is an Ethernet gateway that provides
web monitoring services, a Modbus TCP/IP server,
and a local web page server. End users can collect
information about their off-grid PV system remotely.
One EMC-1 supports all products with MeterBus
ports by bridging MODBUS TCP/IP requests to serve
LiveView pages for each product.
USB Communications Adapter (UMC-1)
A modular unit that uses a USB-B plug, usually
from a USB A-B computer cable, and an RJ-11
plug to connect with a Morningstar controller’s
MeterBus port, for monitoring and programming
using MSView PC software.
PC MeterBus Adapter
TM
(Model: MSC)
The MSC converts the MeterBus RJ-11 electrical
interface to an isolated standard RS-232 interface
which enables communication between the
ProStar and a PC.
The MSC can be used for
programming custom charging set-points, and for
logging data in MSView. See Section 4.5 for more
information on programming.
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.
• Loose power connections and/or corroded wires
may result in resistive connections that melt wire
insulation, burn surrounding materials, or even
cause fire. Ensure tight connections and use cable
clamps to secure cables and prevent them from
swaying in mobile applications.
• 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.
• The ProStar battery connection may be wired to
one battery or a bank of batteries. The following
instructions refer to a singular battery, but it is
implied that the battery connection can be made
to either one battery or a group of batteries in a
battery bank.
• The ProStar uses stainless steel fasteners, an
anodized aluminum heat sink, and conformal
coating to protect it from harsh conditions.
However, for acceptable service life, extreme
temperatures and marine environments should be
avoided.

Installation ProStar Operator’s Manual 23
22
3.0
• 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. Connection to any other type
of power source e.g. wind turbine or generator may
void the warranty. However, other power sources
may be connected directly to the battery.
• The connector terminals will accept a maximum
wire size of AWG #6 / 16 mm2 (solid/multi-strand)
or #8 AWG / 10 mm2(fine strand). Use an insulated
flathead 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 conductor strands coming free out of
the connection screw, and possible contact with the
metal enclosure.
WARNING: Solar and battery fuses or DC
breakers are required in the system. These
protection devices are external to the ProStar
controller, and must be a maximum of 20 Amps for the
ProStar-15/M, and 50 Amps for the ProStar-30/M.
AVERTISSEMENT : Fusibles solaires et de
batterie ou CC des disjoncteurs sont néces-
saires dans le système. Ces dispositifs de protection
sont externes au contrôleur ProStar et doivent être au
maximum de 20 A pour le ProStar-15 / M et de 50 A
pour le ProStar-30 / M.
WARNING: All breakers must be properly
rated for wire ampacity, which may require less
than the maximum breaker sizes referenced above.
AVERTISSEMENT : Tous les disjoncteurs doi
vent être correctement dimensionnés pour
l'intensité du fil, ce qui peut nécessiter moins que
les tailles de disjoncteur maximales mentionnées
ci-dessus.
WARNING: Minimum over-current
protection device interrupt ratings must be
2000A for 12V systems, and 4000A for 24V systems.
AVERTISSEMENT : Surintensité minimale
Les valeurs nominales d'interruption des dis-
positifs de protection doivent être de 2 000 A pour les
systèmes 12 V et de 4 000 A pour les systèmes 24 V.
NOTE: Carefully observe the LEDs after
each connection. The LEDs will indicate
proper polarity, and a secure connection.
3.2 Configuration
The DIP switch block shown in Figure 3.1 below is
used to set the operating parameters for the ProStar.
Figure 3.1. DIP Switch Block to set charging parameters

Installation ProStar Operator’s Manual 25
24
3.0
Switch 1: Load / Lighting
Mode Switch 1
Normal OFF
Lighting ON
Switches 2, 3: System Voltage
Three (3) system voltage configurations are available
as shown in the table below:
System voltage Switch 2 Switch 3
Auto OFF OFF
12 OFF ON
24 ON OFF
NOTE: Before connecting the battery, measure
the open-circuit voltage. It must be over 10
Volts to start the controller. If the system voltage
DIP 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. The
12/24V auto selection is only done at start-up, and
the detected system voltage will never change during
operation.
It is recommended to set DIPs 2 and 3 to the correct
system voltage setting. Only use the default auto-
detect setting if the nominal system voltage is not
known.
Switches 4, 5, 6: Battery Type Selection
Preset ProStar battery charging options are shown
in table 3-1 below. All voltage settings listed are for
nominal 12 Volt batteries. Multiply the voltage settings
by two (2) for 24 Volt systems.
NOTE: The charging profiles below are general
guidelines for use at the operator’s discretion. Consult
the battery manufacturer for optimal battery charge
settings.
Battery Charging Set-points (@ 25°C):
[multiply voltages by (2) for 24 Volt systems]
Switch 7: Battery Equalization
Mode Switch 7
Manual Equalization OFF
Auto Equalization ON
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
150
off-off-on
2 - Sealed*
14.15
13.50
14.40
150
60
120
28
off-on-off
3 - Sealed*
14.30
13.50
14.60
150
60
120
28
off-on-on
4- AGM/Flooded
14.40
13.50
15.10
180
120
180
28
on-off-off
5 - Flooded
14.60
13.50
15.30
180
120
180
28
on-off-on
6 - Flooded
14.70
13.50
15.40
180
180
240
28
on-on-off
7 - L-16
15.40
13.40
16.00
180
180
240
14
on-on-on
8 - Custom
Custom
Custom
Custom
Custom
Custom
Custom
Custom
* “Sealed” ba�ery type includes gel and AGM ba�eries

Installation ProStar Operator’s Manual 27
26
3.0
Switch 8: Current Switching
Mode Switch 8
PWM switching OFF
Slow switching ON
The default (PWM) switching setting (OFF / down) operates
at 300Hz. If load or system noise is an issue, DIP 8 can be set
(ON-up) for slow switching at 1Hz. Standard PWM switching is
recommended when system noise is not a problem.
3.3 Mounting
Inspect the controller for shipping damage. Mount the
ProStar to a vertical surface (4-#8 stainless steel self-
tapping screws are included). Tighten the mounting
screws using care not to crack the plastic case. Do not
install directly over an easily combustible surface since
the heat sink may get hot under certain operating
conditions.
NOTE: The heat sink must be in a vertical
position (fins up and down).
For proper air flow, allow at least 15 cm (6 in) of space
above and below the controller, and 50 mm (2 in) at
the sides - see Figure 3-2 below. 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 gases can accumulate.
Figure 3-2. Proper Clearances for Passive Cooling
6 in / 150 mm
6 in / 150 mm
2 in /
50 mm

Installation ProStar Operator’s Manual 29
28
3.0
3.4 Wiring
To battery (+) and
(-) terminals for
Not used in this illustration
voltage sensing
To battery for
temperature
sensing
To battery (+)
and (-)
terminals
To load (+)
and (-)
terminals
To properly
sized array
1
4
6
7
2
3
5
REFER TO FIGURE 3.3 WHEN USING THE FOLLOWING
WIRING INSTRUCTIONS
Figure 3-3. Wiring the ProStar
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.
Multiple controllers can be installed in parallel on the
same battery bank to achieve greater total charging
current. In this type of system, each ProStar must have
its own solar array. The load terminals of multiple
controllers can only be wired together if the total load
draw does not exceed the nameplate current of the
LOWEST rated controller.
STEP 2: Battery Voltage Sense Wires
WARNING: Fire Hazard
When connecting Battery Sense Wires, install a
5 Amp fuse in the (+) sense wire, six inches
from the (+) battery terminal.
AVERTISSEMENT : Risque d'incendie
Lors de la connexion des câbles de détec-
tion de batterie, installez un Fusible de 5 A dans le
fil de détection (+), à six pouces de la borne (+) de la
batterie.
Due to connection and cable resistance, voltage drops
are unavoidable in power cables that carry current,
including the ProStar battery cables. If Battery Sense
wires are not used, the controller must use the voltage
reading at the battery power terminals for regulation.
This voltage will be higher than the actual battery bank
voltage while charging the battery.

Installation ProStar Operator’s Manual 31
30
3.0
Battery voltage Sense connection enables the ProStar
to measure the battery terminal voltage precisely
with small gauge wires that carry very little current,
and thus have no voltage drop. The sense wires,
when connected directly to the battery, will improve
battery charging accuracy. Battery voltage sense wires
are recommended if the controller is more than five
meters from the battery.
Generally accepted wiring practice is to limit voltage
drops between the charger and the battery to 2%.
Even properly sized wiring with 2% drop can result in
a 0.29 Volt drop for 14.4V charging. Voltage drops
will cause some undercharging of the battery. The
controller will begin Absorption or limit equalization
at a lower battery voltage because the controller
measures a higher voltage at the controller’s terminals
than is the actual battery voltage. For example, if
the controller is programmed to start Absorption at
14.4V,when the controller “sees” 14.4V at its battery
terminals, the true battery voltage would only be
14.1V, if there is a 0.3V drop between the controller
and battery.
Note that the battery sense wires will not power the
controller, and the sense wires will not compensate
for losses in the power wires between the controller
and the battery. The battery sense wires are used to
improve the accuracy of the battery charging.
The two sense wires, can range in size from 1.0 to 0.25
mm2(16 to 24 AWG), and should be cut to length as
required to connect the battery to the voltage sense
terminals. A 2-position terminal (see Figure 3.3) is
used for the battery sense connection. A twisted pair
cable is recommended but not required. Use UL rated
300 Volt conductors. The voltage sense wires may be
pulled through conduit with the power conductors.
Observing correct polarity, connect both battery
voltage sense wires to the ProStar at the 2-position
Battery Sense terminal, and to battery (+) and (-)
terminals. No damage will occur if the polarity is
reversed, but the controller cannot read a reversed
sense voltage.
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.
NOTE: If the battery input voltage is greater
than 5 Volts different than the Battery Sense,
due to voltage drops or faulty connections, the Battery
Sense input will not be recognized by the ProStar.
A battery voltage sense connection is not required to
operate the ProStar controller, but it is recommended
for best performance.

Installation ProStar Operator’s Manual 33
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3.0
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. Internal Temperature Compensation will be
used if the RTS is not connected. Use of the RTS is
strongly recommended.
AVERTISSEMENT: Risque d'incendie.
Si aucun capteur de température à distance
(RTS) n'est connecté, utilisez le ProStar à moins de 3
m (10 pieds) des piles. La compensation de tempéra-
ture interne sera utilisée si le RTS n'est pas connecté.
L'utilisation du RTS est fortement recommandée.
All charging settings are based on 25°C (77°F). If
the battery temperature varies by 5°C, the charging
setting will change by 0.15 Volts for a 12 Volt battery.
This is a substantial change in the charging of
the battery, and the use of the optional Remote
Temperature Sensor (RTS) is recommended to adjust
charging to the actual battery temperature.
The need for temperature compensation depends
on the temperature variations, battery type, how
the system is used, and other factors. If the battery
appears to be gasing too much or not charging
enough, the RTS can be added at any time after the
system has been installed.
Connect the RTS to the 2-position terminal located to
the left of the (+) Load terminal (see Figure 3.3).
The RTS is supplied with 33 ft (10 m) of 22 AWG (0.34
mm2) cable. There is no polarity, so either wire (+ or
-) can be connected to either screw terminal. The RTS
cable may be pulled through conduit along with the
power wires. Tighten the connector screws to 5 in-lb
(0.56 Nm) of torque. Separate installation instructions
are provided inside the RTS bag.
CAUTION: Equipment Damage
Never place the temperature sensor inside a
battery cell. Both the RTS and the battery
will be damaged.
ATTENTION : Dommages matériels
Ne placez jamais le capteur de température
dans un cellule de batterie. Le RTS et la batterie
sera endommagé.
NOTE: The ProStar will use the local
temperature sensor for compensation if the
RTS is not used.
NOTE: The RTS cable may be shortened if
the full length is not needed. Be sure to
re-install the ferrite choke on the end of the RTS if
a length of cable is removed. This choke ensures
compliance with electromagnetic emissions standards.

Installation ProStar Operator’s Manual 35
34
3.0
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.
For safety, and effective lightning protection, it is
recommended, and may be locally required, that
the negative conductor of the charging system
be properly grounded. For conductor sizing
requirements, refer to the US National Electrical Code,
or applicable local regulations or code.
WARNING: Risk of Fire
DO NOT bond DC system electrical negative
to earth grounding terminal on the controller. Per
NEC, system negative must be bonded to earth
ground at only one point, and through a GFPD, if
required.
AVERTISSEMENT: Risque d'incendie
NE PAS relier le négatif électrique du système
CC à la borne de mise à la terre du contrôleur. Si
requis par le code ou la réglementation locale, le
négatif du système doit être relié à la terre en un seul
point et via un GFPD.
STEP 5: Battery Connections
(at battery
OR solar side,
but NOT both)
System Ground
6 in (150 mm)
Max.
Battery (-)
Battery (+)
+-
12V or 24V
Battery
Fuse or breaker sizing
based on required wire
ampacity
Be sure that DIP switches 2 and 3 are set for 12 or 24V,
as described in Section 3.2.
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.
The 12/24V auto selection is only done at start-up.
With the battery disconnect open, connect the battery
(+) and (-) wires from the battery to controller. DO NOT
CLOSE THE DISCONNECT AT THIS TIME.