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9

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 b 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.

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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