Operator`s Manual
Contents
1. Leds 11 7 3 Protections cce cuoceces ve ehe RR ep Se 11 7 4 Inspection amp 12 7 9 5peclal Fears MUR RAN a ae 12 8 0 BATTERY CHARGING 13 8 1 ProStar Charging 13 8 2 Select Battery Type isses ERE FRU E is 13 8 3 ProStar Charging 13 9 0 TESTING AND 5 14 9 1 Self Diagnostics usse x e RR RATE es 14 9 2 Technical Support xd ERE ER RR RO nd 14 9 3 Testing with Power Supply eet temere een 14 9 4 Troubleshooting 15 10 0 SPECIFICATIONS ic oes ez EEERERRREETEXEE REF EYES 17 SEES 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 Seas 2 0 IMPORTANT SAFETY INF2. Note that the button must be released to start the self test The push button be used to toggle through the displays faster entire self test takes 30 to 45 seconds The load will be turned on for 0 1 second and may flash during the test A short or overload condition could cause a controller restart The following displays will occur examples are used 8 8 8 self test started checking the digital meter segments leu the system voltage 12 24 48 ISA ProStar current rating riS software version installed EUH a fault has been detected see list below d display if no fault is found temperature measured at the controller rP remote temp probe is detected if connected ese temperature at the remote probe if connected SEn battery sense detected if connected 5 1 battery select position 1 2 or 3 d i telecom noise jumper cut change to on off regulation End end of the self test End End display continues if no 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 EG EUN r1 EUG EU EID Ell Eig 13 Rotary switch battery selection failure Voltage reference test failed circuit malfunctions Solar array current fault circuit FETs Load FETs off test load connection FETs shorted Load current fault circuit FETs Load FET
3. 11 4 LVD reconnect 126 12 6 12 6 e PWM regulation 140 1415 144 Float 137 137 13 7 Equalization NWA 14 35 149 15 HVD solar 152 152 15 2 HVD load 153 153 15 3 PWM constant voltage 5mV C cell 25 C ref 30 C to 80 C PWM float equalize HVD see section 8 3 Charge algorithm Temp comp coefficient Temp comp range Temp comp setpoints Equalization Dimensions inch 6 01 x 4 14 x 2 17 153 x 105 x 55 Weight 12 oz 0 34 kg Wire terminals Euro style solid 6 AWG 16 mm2 multistrand 6 AWG 16 mm2 fine strand 8 AWG 10 mm2 Terminal diameter 0 210 in 5 4 mm Torque terminals up to 35 in lb e Ambient temperature 40to 60 C Storage temperature 55 to 85 C Humidity 10096 NC Specifications subject to change without notice Designed in the U S A C C Assembled in Singapore 5 2 501 April 01
4. 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 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 12 ESS SS SSS SS ee 8 0 BATTERY CHARGING INFORMATION The ProStar is an advanced fully automatic solar battery charger No adjustments are re
5. LED should not be on Measure the voltage at the SOLAR terminals with the array still disconnected If battery voltage is measured at the SOLAR terminals and the green LED is on the controller may be defective CAUTION If your ProStar is a positive ground version references above to Battery terminals should be Battery negative terminals 3 LOAD IS NOT OPERATING PROPERLY Check that the load is connected and turned on Confirm that no fuses or circuit breakers in the system are tripped there are no fuses or circuit breakers inside the ProStar Check all connections to the load and battery connections Make sure voltage drops in the system are not too high a voltage drop to the load will reduce the voltage at the load e 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 protection function of the ProStar and the load will be automatically reconnected when the battery is charged by the solar array f the LEDs are blinking the load may have been disconnected for protection from one of the following faults short circuit or overload R G Y sequencing NOTE After 3 automatic retries the fault must be cleared and the load must be switched off or disconnected for 10 seconds or longer to restore power to the load terminals high temperature R Y sequencing high voltage R G sequencing Measure the volta
6. EDs 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 S FAULT INDICATIONS 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 E ee 5 0 DIGITAL METER amp 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
7. ORMATION Always Put Safety First e 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 e SAVE these instructions for future reference ee a ae 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 ProSta
8. PROSTAR SOLAR CONTROLLERS OPERATOR S MANUAL 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 MORNINGSTAR corporatio 1098 Washington Crossing Road Washington Crossing PA 18977 USA phone 215 321 4457 fax 215 321 4458 email info amp morningstarcorp com PROSTAR DIMENSIONS 6 01 153 75277 136 5 1 0 GENERAL 4 2 0 IMPORTANT SAFETY INFORMATION 4 3 0 QUICK START INSTRUCTIONS 4 40 6 2 8 lt 4 552 vee 5 5 0 DIGITAL METER amp MANUAL DISCONNECT 6 5 1 Digital 6 5 2 Manual DISSOHBCE 24 Native Rene wat eria 6 5 3 Display Disconnects amp Protections 6 5 4 Self Diagnostics 6 6 0 INSTALLATION INSTRUCTIONS 8 6 1 General Installation Notes s cote eR nnn 8 6 2 Installation alae be ea quie d Rara a ke 8 7 0 RIP e M en pw lr quas 10 7 1 Operators Tasker 53245 lt lt ee Pin keels abe ss 10 7 2 Operations amp Functions
9. 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 15 Check that the proper battery type has been selected Disconnect the solar array and remove the battery wire from the ProStar battery positive terminal Wait a few seconds and reconnect the battery positive terminal leaving the solar array disconnected After start up the green CHARGING
10. 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 battery 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
11. c functions to protect both the controller and the solar system Battery charging is also fully automated see section 8 0 The only manual tasks performed by the operator are a Installation see section 6 2 b Battery type selection see section 6 2 Step 7 c Disconnect button Self test see section 5 2 and 5 4 d Reset if a load short circuit does not automatically clear see section 7 3 e Maintenance see section 7 4 10 7 2 OPERATIONS FUNCTIONS The solar system operator should become familiar with the following operating functions of the ProStar controller Refer to the Technical Specifications section 10 0 for actual setpoints and other parameter values 100 Solid State All power switching is done with FETs No mechanical relays are used in the controller Battery Charge Regulation The ProStar is a PWM battery charger See the next section 8 0 for a description of battery charging Low Voltage Load Disconnect LVD An automatic load disconnect protects the battery from deep discharge The load automatically reconnects when the battery recovers A 4 minute delay prevents false LVD disconnects Low Voltage Warning The red status LED will blink at low battery capacity to warn of a possible LVD Parallel Controllers ProStar controllers work very well in parallel configurations No blocking diodes are required Each controller must have an independent and separate solar subarray and a load that does not excee
12. d contact is made STEP 8 Confirm Installation After the connections are completed observe the LEDs to make sure the controller is operating normally for system conditions If the optional digital meter is provided observe that the display is scrolling with proper voltage and amperage values A self test can be performed with the digital meter see section 5 4 STEP 9 Grounding For safety and effective lightning protection the negative conductor of the solar system should be properly grounded see 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 per UL recommendations No switching or measurement is done in the negative current path NOTE For positive ground versions the Solar Battery and Load POSITIVE terminals are connected together inside the ProStar The positive system conductor must be properly grounded Make sure the upper label of the ProStar indicates Positive Ground above the version number to confirm this is a positive ground ProStar controller EE 7 0 OPERATION 44 7 1 OPERATOR S TASKS The ProStar is a fully automatic solar system controller that includes many electroni
13. d the controller s rating Auxiliary Generators Engine generators and other sources of power may be connected directly to the battery for charging It is not necessary to disconnect the ProStar from the battery However do not use the ProStar to regulate these 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 refer to section 7 5 below 7 3 PROTECTIONS The ProStar is fully protected against system faults listed below Recovery is automatic except where noted below Refer to sections 4 0 and 5 0 for fault indications Solar short circuit and overload fully automatic recovery Load short circuit and overload after 3 automatic load reconnect attempts 10 seconds between each attempt the fault must be cleared and the load must be turned off or disconnected for 10 seconds or longer to restore power to the load terminals Reverse polarity fully protected except per Caution below Battery disconnected the load is protected from voltage spikes High temperature first the solar is disconnected then the load will be disconnected auto reconnects High battery voltage first the solar is disconnected then the load will be disconnected auto reconnects Very low battery voltage brownout protection auto recovery into LVD state Battery select error defaults to gel battery set
14. ge at the BATTERY terminals If above LVD and no faults are present the load should have power Then measure the voltage at the LOAD terminals and if there is no voltage present the controller may be defective NOTE For more technical and testing information visit Morningstars Website www morningstarcorp com 16 SESS ae 10 0 TECHNICAL SPECIFICATIONS 44 Note Values for 12V versions 24V versions 2 times 48V are 4 times the 12V values unless noted otherwise Accuracy 12V 40 mV 24V 60 mV 48V 80 mV e Min voltage to operate 12 24V 8V 48 V 15V Self consumption 12 24V 22 25 mA 48V 28 mA LVD current coefficient 20 mV amp load 24V 48V 40 80 mV e High temp shutdown 70 C disconnect solar 80 C disconnect load 60 C reconnect load 50 C reconnect solar Voltage drops max solar battery 0 2 V battery load 0 12 V Operating life 15 years Transient surge protect pulse power rating 1500 watts response 5 nanosec Type LCD Temp rating 30 to 85 C Voltage accuracy 0 5 Current accuracy 2 0 Self consumption 1 mA Falling V Rising V G to Y 12 1 13 1 YtoG YtoBlinkR 117 12 6 Blink R to Y BinkRtoR 11 4 12 6 Rto Y 17 BATTERY SETPOINTS 25 C Gel Sealed Flooded LVD 114 114
15. o be added Regulates to 14 4V with 14 9V and 15 1V equalizations 12V battery The above values are 2 times for 24V and 4 times for 48V The battery type selection can be changed at any time 8 3 PROSTAR CHARGING FEATURES Other ProStar capabilities for best battery life follow Night Disconnect The solar array automatically disconnects at night to prevent reverse current leakage from the battery 13 Battery Sense Good battery performance requires accurate charging Voltage drops in the battery power cables can distort the battery charging The Sense wires eliminate the voltage drops for optimized charging Temperature Compensation Four control setpoints 25 C reference are compensated for temperature PWM regulation float equalization high voltage disconnect The charging is compensated by 5 mV C cell 30mV C for a 12V battery Compensation is limited to minus 30 C Remote Temperature Probe An optional probe is available to measure temperature at a location away from the controller This requires soldering 2 wires to the ProStar PCB See section 7 5 Battery Equalization Sealed Flooded Calendar 25 days Equalization voltage 14 35 14 9 Cumulative time 1 hour 1 hour Time starts above V 14 3 14 6 Battery History flooded only Battery voltage falls below V N A 11 7 Equalize voltage 15 1 Cumulative time 2 hours Time starts above V 14 6 Reset 25 day calendar yes The above battery setpoint
16. quired except to select the battery type at installation see section 8 2 below 2 4 PWM REGULATION 3 CHARGE FLOAT NIGHT NIGHT 8 1 PROSTAR CHARGING METHOD The ProStar uses 4 stages of charging for rapid efficient and safe battery charging These are shown in the diagram below 1 Recharging with 10096 of available solar energy 2 PWM constant voltage regulation to prevent heating and excessive battery gassing Pulse charging to restore full battery capacity 3 Float After battery is fully recharged ProStar reduces to a float or trickle charge The transition depends on battery history A load that exceeds available solar output will return ProStar to the PWM mode 4 Equalize A boost charge that depends on elapsed time and battery history Flooded cells receive a vigorous equalization sealed batteries 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 algorithms These are broadly defined as the following battery types as noted on the lower label 1 Gel Some gel and other battery types recommend lower regulation voltages and no equalization This setting regulates to 14 0V for a 12V battery 2 Sealed AGM maintenance free and some types of gel batteries Regulates to 14 15V 12V battery with 14 35V boost charging 3 Flooded Vented cells that require water t
17. r to a vertical surface Allow space above and below the controller for air flow The heat sink MUST be in a vertical up amp down position 2 Make sure the Solar and Load currents will not exceed the ratings of the ProStar version being installed 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 fault the LEDs will begin blinking Refer to section 4 0 of this manual to identify the fault CHARGING TEMP SENSOR BATTERY 2 SEALED TYPE 3 FLOODED PV BATTERY 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 See 4 0 LED INDICATORS The 4 L
18. rge 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
19. s are 2 times for 24V and 4 times for 48V SSS 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 of the ProStar This will test for almost all failure modes of the ProStar and display any faults that are found If the self diagnostic test indicates that no failures were found it is very likely that the problem is with the solar system or battery 9 2 TECHNICAL SUPPORT Additional technical information and support can be found at Morningstar s Website www morningstarcorp com 9 3 TESTING WITH A POWER SUPPLY The ProStar can be tested with a power supply used in place of either the solar array input or the battery To avoid damage to the ProStar observe the following cautions Current limit the power supply to no more than half the ProStar rating Set the power supply to 15 volts DC or less for 12V systems 30V for 24V systems and 60V for 48V systems Connect only one power supply to the controller Failure to follow these precautions may void the warranty 14 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 cha
20. s on test load circuit FETs open Internal temp sensor out of range high Internal temp sensor out of range low Remote temp probe out of range Battery sense fault battery V drop over 5V no Sense negative connection In addition to the self test observe the solar and load currents displayed in the meter The self diagnostics plus the currents displayed in the meter will provide a comprehensive test of the ProStar Some faults may exist that are not detected by the self test but the large majority of potential faults will be tested and reported in this self diagnostic test Refer to section 9 0 for more information p 6 0 INSTALLATION INSTRUCTIONS The ProStar is installed in 10 steps Follow the procedure in section 6 2 for a proper installation and best performance 6 1 GENERAL INSTALLATION NOTES The ProStar uses stainless steel fasteners an anodized heat sink and conformal coating to protect from harsh conditions However for acceptable service life extreme temperatures and marine environments should be avoided The ProStar prevents reverse current leakage at night so a blocking diode is not required in the system The ProStar is designed to regulate ONLY solar photovoltaic power Do not connect it to any other type of power generator Do not attempt to regulate a wind turbine However other power sources can be connected directly to the battery The connector terminals will accept a maxim
21. ting flashes LEDs Temperature sensor failure a remote probe failure defaults to the internal temperature sensor which defaults to a fixed 25 C if it fails CAUTION One source of potential damage to the controller is a reversed battery polarity together with a polarized or short circuited load 11 7 4 INSPECTION amp MAINTENANCE The following inspections and maintenance tasks are recommended at least two times per year for best controller performance 1 Dr Os E ope 52 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 Confirm that the maximum current of the solar array and load does not exceed the ProStar ratings Tighten all the terminals Inspect for loose or broken wire connections Check that the controller is securely mounted in a clean protected environment Check that the air flow and the ventilation holes are not blocked Inspect for dirt insects nests and corrosion 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 B Telecom 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
22. um wire size of AWG 6 16 mm2 solid multistrand or AWG 8 10 mm2 fine strand Use a flathead insulated screwdriver and torque tightly up to 35 in lb Fuses or DC disconnects may be required in the system These protection 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 the wiring connection diagram in section 3 0 STEP 1 Mounting Inspect the controller for shipping damage Mount the ProStar to a vertical surface 4 stainless steel 8 self tapping screws are included Tighten the mounting screws using care not to crack the plastic case Do not install directly over an easily combustible surface since the heat sink may get hot under certain operating conditions NOTE Heat sink must be in a vertical position fins up and down Allow at least 15 cm 6 inches space above and below the controller for air flow Install in an area protected from direct rain and direct sun If the controller is installed in an enclosure some ventilation is recommended Do not locate in an enclosure where battery gasses can accumulate STEP 2 Ratings Confirm that the solar array and loads will not exceed the current rating of the ProStar version being installed Multiple ProStar units can be paralleled at the system battery to increase the solar capacity but do not parallel loads NOTE The
23. 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 9 STEP 7 Battery Type Selection Using a small screwdriver turn the rotary switch to select the Battery Type There are 3 choices see section 8 2 1 Gel battery 2 Sealed battery 3 Flooded battery A proper selection will flash the 3 Status LEDs together 1 time for Gel 2 times for Sealed and 3 times for Flooded If the rotary switch does not make a good contact with one of the 3 selections the 3 LEDs will start flashing together and continue until a goo
24. 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 amp 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
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