ProStar PS-15, PS-30, PS-15M-48V User Manual

SOLAR CONTROLLERS

OPERATOR’S MANUAL

P

RO

S

TARTAR -12

PROSTAR VERSIONS INCLUDED IN THIS MANUAL

PS-15 PS-30 PS-15M-48V

Rated 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 MANUAL

1098 Washington Crossing Road

Washington Crossing, PA 18977 USA

phone: [phone]

fax: [phone]

email: [e-mail]

3.50

PROSTAR DIMENSIONS

(89)

4.14

(105)

6.01

(153)

5.37

(136)

.18

(4.57)

2.17
(55)

inches (mm)

3

CONTENTS

1.0 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.0 IMPORTANT SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . 4

3.0 QUICK START INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.0 LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5.0 DIGITAL METER & MANUAL DISCONNECT . . . . . . . . . . . . . . . . 6

5.1 Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5.2 Manual Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5.3 Display Disconnects & Protections . . . . . . . . . . . . . . . . . . . . . 6

5.4 Self-Diagnostics (Self-Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6.0 INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8.0 BATTERY CHARGING INFORMATION . . . . . . . . . . . . . . . . . . . . . 13

8.1 ProStar Charging Method. . . . . . . . . . . . . . . . . . . . . . . . . . 13

8.2 Select Battery Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

8.3 ProStar Charging Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9.0 TESTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 14

9.1 Self-Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

9.2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

9.3 Testing with a Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 14

9.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

10.0 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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1.0 GENERAL INFORMATION

Thank you for selecting the ProStar solar controller. This second generation ProStar adds new
features and protections using highly advanced technology. Morningstar’s patented PWM battery
charging algorithm has also been further optimized for longer battery life and improved system
performance.

Many functions of the ProStar are unique. Although the ProStar is very simple to use, please take
the time to read this operator’s manual and become familiar with the controller. This will help you
to make full use of the many advantages the ProStar can provide for your solar system.

2.0 IMPORTANT SAFETY INFORMATION

”Always Put Safety First“

• Be very careful when working with batteries. Wear eye protection. Have fresh water
available to wash and clean any contact with battery acid.

• Charge only lead-acid batteries that are properly sized for the system.

• Explosive battery gasses can be present during charging. Be certain there is enough
ventilation to release the gasses.

• Use insulated tools and avoid metal objects near 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 disconnects may be required in the system. These protective devices
are not part of the ProStar controller.

• Avoid large voltage drops in the battery wires. Use the Battery Sense connection for
best battery charging and system performance.

• Do not allow water to enter the controller.

• Avoid touching the controller heat sink. Under certain operating conditions, the heat
sink can become hot.

• Install the controller in a vertical position with adequate space for ventilation.

• Ensure that the system is properly grounded.

• SAVE these instructions for future reference.

3.0 QUICK START INSTRUCTIONS

This section provides a brief overview of how to get started using the ProStar controller. However,
please review the entire manual to ensure best performance and years of trouble-free service.

1. Mount the ProStar to a vertical surface. Allow space above and below the controller
for air flow. The heat sink MUST be in a vertical (up & down) position.

2. Make sure the Solar and Load currents will not exceed the ratings of the ProStar
version being installed.

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)

5

7

2

TEMP. SENSORCHARGING

3

1

1 – GEL

BATTERY

2 – SEALED

TYPE

PV

+

5

3 – FLOODED

BATTERY

–

+

+

SENSE

4

+

BATTERY

–

3

9

BATTERY STATUS

–

–

+

10

LOAD

6

BLINK: LOW
ON: LVD

–

1



UP

6

FAULT INDICATIONS (G = green; Y = yellow; R = red)

G/Y/R blinking together – battery select fault
R – Y sequencing – high temperature disconnect
R – G sequencing – high voltage disconnect
R/G – Y sequencing – load short circuit or overload

5.0 DIGITAL METER & MANUAL DISCONNECT

A digital meter is available with the ProStar controller as an option. If your version includes the
meter display, this section will describe the information that can be displayed with the meter, and
the added capabilities that are enabled by the push button switch.

5.1 DIGITAL METER

A precision 3-digit digital meter will continuously display battery voltage, solar current, and the
load current. The meter automatically scrolls through these 3 displays. The 3 red LEDs will
indicate which parameter is being displayed.

The digital meter will operate from –30°C to +85°C. The values displayed are calibrated
electronically in production and are accurate to within a few percent. Please note, however,
that if the Battery Sense is not connected, the voltage displayed will be in error 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 controller back to normal operation.

LOAD OFF: A brief push of the button (less than 2 seconds) will disconnect the
Load. The Solar remains on and charging.

LOAD AND SOLAR OFF: If the button is held down for 2 seconds, the Solar will
also be disconnected.

When the button is pushed, the red LED inside the cap will light. In addition, the Load or both
Load and Solar will display “OFF“ in the digital meter to indicate the disconnected state.

5.3 DISPLAY DISCONNECTS & PROTECTIONS

The following protection functions and disconnect conditions will be displayed in the digital
meter when they occur:

LUD LVD – low voltage load disconnect (load only)
HUD high voltage disconnect (both solar and load)
HOT high temperature disconnect (both solar and load)
OCP overcurrent and short circuit protection (load, solar overcurrent)

0.0 short circuit protection (solar only)

5.4 SELF-DIAGNOSTICS (SELF-TEST)

If the push button is held down for 4 seconds, the ProStar will go into automatic self-diagnostics.
Note that the button must be released to start the self-test.