Morningstar ProStar MPPT Series Installation, Operation And Maintenance Manual Download Page 29

Operation

ProStar MPPT Operator’s Manual

53

52

4.0

Lighting Control Mode (DIP 1 ON)
A quick press of the push-button will conduct a ten minute 

lighting test. A lighting test is used to verify correct wiring in 

the load circuit and /or verify that the lighting components 

are operational. The lighting test will override LVD for ten 

minutes - the override duration is not programmable.
•  Press and hold the push-button for five seconds to initiate 

or stop an Equalization (EQ).

Reset PS-MPPT to Factory Settings

To restore factory settings:  Disconnect PV; disconnect     

battery power; press and hold down the push-button;       

re-start the PS-MPPT by connecting the battery; keep the 

push-button depressed for 3-5 secs, until the battery LEDs 

start to cycle R-Y-G.  
A Custom Edit Settings fault will occur.  See Section 5 for 

details. The unit will need to be re-powered to resume     

normal operation.    

4.6 Alarms

Solar Overload

No LED indication. The ProStar MPPT will limit battery     

current to the 25 or 40 amp maximum rating. An over-sized 

solar array will not operate at peak power. The solar array 

should be less than the ProStar MPPT nominal max. input 

power rating for optimal performance.  See Section 7.0 -  

Technical Specifications for more information.

High Temperature Current Limit

The ProStar MPPT will limit the solar input current if the 

heatsink temperature exceeds safe limits. Solar charge 

current will be tapered back (to 0 amps if needed) to 

reduce the heatsink temperature. The Appendix B de-rating 

graphs indicate maximum ambient temperatures at which 

the ProStar MPPT will operate with full-rated current; as 

indicated in each graph, maximum ambient temperature 

depends on array input voltage. Actual de-rating 

temperatures lower than specified in the graphs indicate 

insufficient airflow. Maximum charging current depends 

on many factors, and good ventilation can greatly reduce 

the amount of de-rating. If the controller frequently reports 

this alarm condition, corrective action should be taken to 

provide better air flow, or to move the controller to a cooler 

location.

High Input Voltage Current Limit

The ProStar MPPT will limit the solar input current as the 

solar array Voc approaches the maximum input voltge          

rating. The array Voc should never exceed the 120 volt 

maximum input voltage - see the array voltage de-rating 

graph in Appendix.

 

Current Limit

The array power exceeds the rating of the controller. This 

alarm indicates that the ProStar MPPT is limiting battery   

current to the maximum current rating. 

RTS Open

The Remote Temperature Sensor is not connected to the 

controller. Use of the RTS is recommended for proper 

battery charging.

Heatsink Temperature Sensor Open / Shorted

The heatsink temperature sensor is damaged. Return the 

controller to an authorized Morningstar dealer for service.

Battery Sense Out of Range / Disconnected 

(only alarm 

with LED indications)
Error status LED:  Flashing red. Battery status LEDs: R/Y 

- G/Y sequencing.  A battery sense wire is disconnected.  

Inspect the battery sense connections. This alarm is set 

when the voltage at the battery sense terminals differs 

by more than five volts from the voltage at the battery 

terminals.

Uncalibrated

The controller was not factory calibrated. Return the       

controller to an authorized Morningstar dealer for service.

Summary of Contents for ProStar MPPT Series

Page 1: ...ation Operation and Maintenance Manual www morningstarcorp com ProStar MPPT TM MODELS PS MPPT 25 PS MPPT 25M PS MPPT 40 PS MPPT 40M MAXIMUM POWER POINT TRACKING For the most recent manual revision see...

Page 2: ...36 4 1 TrakStar MPPT Technology 36 4 2 Battery Charging Information 38 4 3 Load Control Information 48 4 4 LED Indications 50 4 4 1 Power up 50 4 4 2 Status LED 50 4 4 3 State of charge LEDs 51 4 5 Pu...

Page 3: ...d installations et d utilisation du contr leur solaire ProStar MPPT Les symboles suivants sont utilis s dans ce manuel pour indiquer des conditions potentiellement dangereuses ou des consignes importa...

Page 4: ...allow water to enter the controller Install the ProStar MPPT in a location that prevents casual contact The ProStar MPPT heatsink can become very hot during operation Use insulated tools when working...

Page 5: ...with connection to the ProStar MPPT ground terminal The grounding conductor must be secured against any accidental detachment Pr cautions de S curit D installation AVERTISSEMENT L appareil n est pas f...

Page 6: ...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...

Page 7: ...bagues bijoux et autres objets m talliques avant de travailler avec des piles Porter des bottes et des gants de caoutchouc Utiliser des outils avec poign es isolantes et vitez de placer des outils ou...

Page 8: ...otherwise a maximum of 6 AWG wire Includes battery voltage sense terminals Digital meter display options Optional remote battery temperature sensor 5 year warranty see Section 6 0 2 0 GENERAL INFORMAT...

Page 9: ...la classe B est conforme a la norme NMB 003 du Canada 2 3 Versions and Ratings PS MPPT 25 Rated for maximum 25 amps continuous current battery or load Designed for 12 or 24 VDC systems PS MPPT 25M In...

Page 10: ...Power connections for Load and cable terminations 7 Battery Positive and Negative Terminals Power connections for Battery and cable terminations 8 Local Temperature Sensor Compensates charging based...

Page 11: ...ound fault Protection Device GFPD 150V The GFPD 150V detects power source ground faults and interrupts current as required by the U S National Electrical Code Wire Box for ProStar MPPT A modular wirin...

Page 12: ...nections 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 Pre...

Page 13: ...0 M WARNING Installation must comply with all US National Electrical Code and Canadian Electrical Code requirments Breakers and fuses may require lower ratings than referenced above so as not to excee...

Page 14: ...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...

Page 15: ...temperature sensing To battery and terminals To load and terminals To properly sized array 2 3 1 7 5 6 4 3 4 Wiring Figure 3 3 Wiring the PS MPPT REFER TO FIGURE 3 3 WHEN USING THE WIRING INSTRUCTION...

Page 16: ...ecommended if the controller is more than three meters 10 ft from the battery Generally accepted wiring practice is to limit voltage drops between the charger and the battery to 2 Even properly sized...

Page 17: ...cated between the battery and chassis ground terminal lugs see figure 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 scr...

Page 18: ...syst me la mise la terre au niveau du contr leur Selon les exigences par le code local ou les r f rences le c t n gatif du syst me doit tre mis la terre par un GFPD un seul point For safety and effect...

Page 19: ...way to break the PV connection when necessary DO NOT CLOSE THE BREAKER AT THIS TIME 40 Volt MODULE 40 Volt MODULE 40 Volt MODULE SOLAR Solar Disconnect SOLAR 120Voc Maximum EARTH GROUND STEP 7 Load C...

Page 20: ...r connection LOAD LOAD 40 or 55 Amp Fuse depending on model If the load does not turn on it could be for various reasons the ProStar MPPT is in LVD red LED on there is a short circuit in the load LEDs...

Page 21: ...tems where the solar array is of a higher nominal voltage than the battery as described in the next section 4 0 OPERATION High Voltage Strings and Grid tie Modules Another benefit of TrakStar MPPT tec...

Page 22: ...extended by 30 minutes if the battery discharges below 12 50 volts 12V system the previous night The Absorption set point is temperature compensated through either the on board local temperature sens...

Page 23: ...the electrolyte gases The green SOC LED will blink rapidly two 2 times per second during equalization charging The duration of the equalize charge is determined by the selected battery type See table...

Page 24: ...ings table see table 4 1 in this section shows two sealed battery settings with an Equaliza tion cycles These are minimal boost cycles to level indi vidual cells This is not an equalization and will n...

Page 25: ...Absorption Extension Voltage time hrs Figure 4 3 Absorption Extension Charging Profile If battery voltage discharges below 12 50 volts 25 00 volts 24V the previous night Absorption charging will be ex...

Page 26: ...threshold voltage The diagram shows where Float stage would have occurred if Float was not canceled Equalize Time out 1 00 2 00 3 00 4 00 5 00 6 00 Absorp V Bulk Float Equalize Equalize timeout time...

Page 27: ...sistance Current Compensation All LVD and LVR set points are current compensated Under load the battery voltage will sag in proportion to the current draw of the load A short term large load could cau...

Page 28: ...briefly every 5 seconds heartbeat indication flickers the Status LED off briefly every 5 seconds Table 4 4 Status LED Definitions NOTES 1 R flashing is generally a user addressable fault error 2 R cha...

Page 29: ...h the ProStar MPPT will operate with full rated current as indicated in each graph maximum ambient temperature depends on array input voltage Actual de rating temperatures lower than specified in the...

Page 30: ...Manual Insert Clear Resettable Ah Clear Total Ah Serial No Firmware Version Battery Type Absorption Voltage Float Voltage EQ Voltage Input Mode System Voltage 4 7 2 Programming in MSView Beyond the pr...

Page 31: ...1 4 5 6 ON and the unit programmed custom timing will be in effect With DIP 1 OFF down all lighting control functions are disabled Using either MSView or the meter display four channels are available...

Page 32: ...rie pourrait devenir trop charg e Test entre toutes les bornes et la masse avant de toucher Schedule Maintenance Items 2 weeks after installation Re tighten power terminal connections to specified tor...

Page 33: ...OOTING disconnected A small overload could take a few minutes to disconnect The ProStar MPPT will attempt to reconnect the load two 2 times Each attempt is approximately 10 seconds apart If the overlo...

Page 34: ...ry status LEDs R Y G sequencing While rare if battery current exceeds approximately 130 of the controller s output current rating this fault can occur The fault is generally related to fast large batt...

Page 35: ...oStar MPPT Battery voltage must be 10 vdc or greater If the voltage on the battery terminals of the controller is between 10 and 35 vdc and no LEDs are lit contact your authorized Morningstar dealer f...

Page 36: ...claim Morningstar will pay the return shipping charges if the repairs are cov ered under the warranty WARRANTY EXCLUSIONS AND LIMITATIONS This warranty does not apply under the following conditions D...

Page 37: ...ank you for your business and we look forward to assisting you WARRANTY CLAIM PROCEDURE 1 Before proceeding please refer to product manual including Troubleshooting section 2 Contacting your authorize...

Page 38: ...et points Absorption Float Equalize HVD and HVDR solar 7 0 TECHNICAL SPECIFICATIONS Battery Charging Set points 25 C multiply voltages by 2 for 24 volt systems Current Compensation 12 volt systems 15...

Page 39: ...Humidity 100 n c Tropicalization Conformally coated PCBs Marine rated terminals For hazardous location IECEx ATEX applications see the addendum part no MS 003244 EN to this manual Protections Power up...

Page 40: ...atts E ciency ProStar MPPT E ciency 24 Volt System 62 Vmp 93 Vmp APPENDIX B De rating Graphs Battery Current vs Array Voltage Battery Current vs Array Voltage Array Voltage Volts O V E R V O L T A G E...

Page 41: ...systems solid copper 2 voltage drop 1 Way Wire Distance meters 12 Volt System Wire Size mm2 40A 35A 30A 25A 20A 15A 10A 5A 70 10 24 11 71 13 66 16 39 20 49 27 32 40 98 81 95 50 8 12 9 28 10 83 12 99 1...

Page 42: ...01 6 69 10 03 20 06 10 1 58 1 80 2 10 2 52 3 15 4 21 6 31 12 62 6 0 99 1 13 1 32 1 59 1 98 2 64 3 97 7 93 4 0 62 0 71 0 83 1 00 1 25 1 66 2 50 4 99 2 5 0 39 0 45 0 52 0 63 0 78 1 05 1 57 3 14 Table C...

Page 43: ...0 32 0 36 0 42 0 50 0 63 0 84 1 26 2 52 Table C 6 Maximum 1 way wire distance for 12 Volt systems stranded copper 2 voltage drop 2 Voltage Drop Charts for 90 C Solid Copper Wire 1 Way Wire Distance fe...

Page 44: ...mperature as defined in the following table Wire Ampacity Key Exceeds wire ampacity at 60 C ambient temperature Exceeds wire ampacity at 50 C ambient temperature Exceeds wire ampacity at 40 C ambient...

Page 45: ...0 6 3 CISPR 22 Low Voltage Directive IEC EN 62109 1 MORNINGSTAR CORPORATION 2 1 Hazardous Locations for IECEx ATEX Applications IECEx ETL 20 0066X ITS20ATEX25933X IECEx Ex ec ic IIC TX Gc ATEX II 3G E...

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