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15

9.4 TROUBLESHOOTING

The ProStar is assembled with automated equipment, tested with computers, and is protected
from faults. It is usually worthwhile to troubleshoot the entire solar system for faults, since the
ProStar will generally not be the cause of a problem. Most problems will be caused by wiring
connections, batteries unable to hold a charge, or faulty loads.

CAUTIONS:

1. Troubleshooting should be done by qualified personnel.

2. A battery can cause serious damage if shorted.

3. There are no user serviceable parts, fuses or circuit breakers inside the ProStar.

4. Observe all normal precautions when working with energized circuitry.

NOTE:

If soldering is required, simply solder-through the conformal coating. The

coating is acrylic and does not affect soldering.

1. BATTERY IS NOT CHARGING

• Check the green CHARGING LED above the Solar input. With sunlight on the solar

array, this LED should be on. 

• Check that the proper BATTERY TYPE has been selected.

• Check that all wire connections in the system are correct and tight. Check the

polarity (+/–) of the connections.

• Measure the solar array open-circuit voltage (disconnected from the controller) and

confirm it is normal. If the array voltage is low or zero, repair the fault in the array.

• Confirm that the load is not drawing more energy than the solar array can provide.

• If the BATTERY SENSE terminals are not 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 the battery. Determine if the battery voltage falls at night with

no load. If the battery is unable to maintain its voltage, it may be failing

• Measure the solar input voltage (during daytime) and battery voltage at the ProStar

terminals. If the voltages at the terminals are the same (within about 0.5 volts), the
solar array is charging the battery. If the solar voltage is close to open-circuit (about
20V), and the battery voltage is low, the controller is not charging the battery and
may be defective. Make sure the ProStar is not in regulation (PWM) for this test (see
section 4.0).

NOTE:

If the battery is not being fully recharged, measure the voltage at the

battery terminals on the ProStar, and then at the terminals on the battery.
This should be done at midday with full charging from the solar array 
(and not in PWM regulation). If the ProStar terminals are 1 volt higher
than the battery terminals, for example, this voltage drop will cause the
battery to regulate 1 volt below its desired regulation (PWM) voltage, 
and it will take longer to recharge. In this case, the SENSE terminals
should be connected to the battery for accurate charging. 

2. BATTERY VOLTAGE IS TOO HIGH

• First check the operating conditions to account for temperature compensation (a

15°C / 59°F temperature will increase PWM regulation by 0.3V for a 12V battery)
and automatic equalizations.

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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