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5

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. SENSOR

CHARGING

 BATTERY STATUS

BLINK:

 LOW

ON:

 LVD

4

2

3

1

BATTERY

TYPE

1

 

– 

GEL

2

 

– 

SEALED

3

 

– 

FLOODED

3

10

6

5

BATTERY

5

7

9

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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