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7.4 INSPECTION & MAINTENANCE

The following inspections and maintenance tasks are recommended at least two times per year
for best controller performance.

1. Confirm that the correct battery type is selected. Turn the rotary switch to another

setting and then back to the setting desired, and count the LED flashes.

2. Confirm that the maximum current of the solar array and load does not exceed the

ProStar ratings.

3. Tighten all the terminals. Inspect for loose or broken wire connections. 

4. Check that the controller is securely mounted in a clean, protected environment.

5. Check that the air flow and the ventilation holes are not blocked.

6. Inspect for dirt, insects, nests, and corrosion.

7. Check that the controller functions and LED indicators are correct for the system

conditions at that time.

7.5 SPECIAL FEATURES

Two specialized capabilities will apply to some ProStar owners.

A) Remote Temperature Probe

An optional remote temperature probe can be soldered to the ProStar assembly at
any time. The standard cable length is 25 ft (7.6 m), and this can easily be extended
to 100 ft (30 m) or longer. The 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 remote probe for battery temperature compensation if it is installed.

B) Telecom Noise Jumper

Some telecom equipment will produce noise when the ProStar begins PWM
regulation. If this occurs, a jumper can be cut to eliminate the noise. Instructions
follow:

• First, try to improve the system grounding which often eliminates the noise. The

PWM battery charging provides a significant benefit to the battery, and it is worth
trying to preserve the PWM charging.

• If the noise continues, disconnect the controller and remove the ProStar assembly

from its plastic case.

• Locate a vertical resistor in the upper right hand corner of the board, near the

microcontroller. This is identified as “J11“ on the board.

• Cut one leg of the resistor and separate the leads.

This will convert the battery charging to a typical “on-off“ regulation of the solar
energy. The switching is very slow, so the noise will not be noticeable. The
equalization and float features of the battery charging algorithm are preserved in the
“on-off“ mode.

In the future, this can be reversed back to PWM if the cut jumper leg is soldered
back together. 

RSPSupply  -  1-888-532-2706 -  www.RSPSupply.com

http://www.RSPSupply.com/p-8569-Morningstar-PS-30M-PG-Charge-Controller-12/24V-30A.aspx

Summary of Contents for ProStar PS-15

Page 1: ...Voltage 12 24V 12 24V 48V Digital Meter Option yes yes standard Positive Ground Option no yes yes PROSTAR VERSIONS INCLUDED IN THIS MANUAL 1098 Washington Crossing Road Washington Crossing PA 18977 U...

Page 2: ...136 6 01 153 4 14 105 3 50 89 inches mm 2 17 55 18 4 57 PROSTAR DIMENSIONS RSPSupply 1 888 532 2706 www RSPSupply com http www RSPSupply com p 8569 Morningstar PS 30M PG Charge Controller 12 24V 30A...

Page 3: ...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 Features 12 8 0 BATTERY CHARGING INFORMATION 13 8 1 ProStar Charging...

Page 4: ...ipment manuals before installing the solar system Observe ALL precautions when working with batteries and power electronics Fuses or DC disconnects may be required in the system These protective devic...

Page 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...

Page 6: ...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 controller back to normal operation LOAD OFF A brief push of the...

Page 7: ...detected To terminate the self test push the button The self test can be repeated to confirm the result Error List E0I Rotary switch battery selection failure E03 Voltage reference test failed circui...

Page 8: ...efully observe the LEDs at each connection The LEDs will indicate proper polarity and a good connection 6 2 INSTALLATION STEPS Refer to the wiring connection diagram in section 3 0 STEP 1 Mounting Ins...

Page 9: ...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 s...

Page 10: ...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 per UL recommendations No switching or measurement is done in the...

Page 11: ...ching noise and filters noise output A properly grounded system will also minimize noise If noise is present in a telecom or radio load refer to section 7 5 below 7 3 PROTECTIONS The ProStar is fully...

Page 12: ...e temperature sensor and the green LED at J12 Instructions are provided with the remote probe The ProStar will automatically select the remote probe for battery temperature compensation if it is insta...

Page 13: ...he battery life Gel cells are not equalized 8 2 SELECT BATTERY TYPE The Battery Type rotary switch allows selection of 1 of 3 charging algorithms These are broadly defined as the following battery typ...

Page 14: ...nts 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...

Page 15: ...and the battery This is a common cause of undercharging batteries See section 6 2 to connect the Battery Sense Check the condition of the battery Determine if the battery voltage falls at night with n...

Page 16: ...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 disconnected due to low battery voltage LVD This is a normal protec...

Page 17: ...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 14 4 Float 13 7 13 7 13 7 Equalization N A 14 35 14 9 15 1 HVD so...

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