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14

Battery Sense:

Good battery performance requires accurate charging. Voltage drops

in the battery power cables can distort the battery charging. The Sense wires
eliminate the voltage drops for optimized charging.

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.

Remote Temperature Probe:

An optional probe is available to measure temperature

at a location away from the controller. This requires soldering 2 wires to the ProStar
PCB. See section 7.5.

Battery Equalization:

Sealed

Flooded

Calendar – 25 days

Equalization voltage

14.35

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

The above battery setpoints are 2 times for 24V, and 4 times for 48V.

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 damage 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 systems (30V for 24V systems

and 60V for 48V systems).

• Connect only one power supply to the controller.

Failure to follow these precautions may void the warranty.

Summary of Contents for ProStar-15

Page 1: ...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 MAN...

Page 2: ...5 37 136 6 01 153 4 14 105 3 50 89 inches mm 2 17 55 18 4 57 PROSTAR DIMENSIONS...

Page 3: ...CTIONS 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 Fea...

Page 4: ...r 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...

Page 5: ...e 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 1...

Page 6: ...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...

Page 7: ...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 E0I Rotary switch b...

Page 8: ...otection 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...

Page 9: ...ery 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 th...

Page 10: ...ee 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...

Page 11: ...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...

Page 12: ...2 probe wires are soldered to the main board assembly between the temperature sensor and the green LED at J12 Instructions are provided with the remote probe The ProStar will automatically select the...

Page 13: ...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 a...

Page 14: ...above V 14 6 Reset 25 day calendar yes The above battery setpoints are 2 times for 24V and 4 times for 48V 9 0 TESTING AND TROUBLESHOOTING 9 1 SELF DIAGNOSTICS If your ProStar includes the optional d...

Page 15: ...ot used there may be excessive voltage drops between the ProStar and the battery This is a common cause of undercharging batteries See section 6 2 to connect the Battery Sense Check the condition of t...

Page 16: ...re voltage drops in the system are not too high a voltage drop to the load will reduce the voltage at the load Check the LED indications on the ProStar If the red status LED is on the load has been di...

Page 17: ...12 1 13 1 Y to G Y to Blink R 11 7 12 6 Blink R to Y Blink R to R 11 4 12 6 R to Y BATTERY SETPOINTS 25 C Gel Sealed Flooded LVD 11 4 11 4 11 4 LVD reconnect 12 6 12 6 12 6 PWM regulation 14 0 14 15 1...

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