ProStar MPPT
TM
Solar Charging System Controller
Installation, Operation and Maintenance Manual
For the most recent manual revisions, see the e-version at:
www.morningstarcorp.com
www.morningstarcorp.com
MODELS
MAXIMUM POWER POINT TRACKING
PS-MPPT-15
PS-MPPT-15M
PS-MPPT-25
PS-MPPT-25M
PS-MPPT-40
PS-MPPT-40M
DIMENSIONS [inches (centimeters)]
7.88
(20.0 )
6.69
(17.0 )
4.92
(13.0)
6.69
(17.0)
2.78
( 7.0 )
SPECIFICATION SUMMARY
PS-MPPT-15
PS-MPPT-25
PS-MPPT-40
Nominal Battery
Voltage
12/24V
12/24V
12/24V
Max. PV OpenCircuit Voltage*
120V
120V
120V
Maximum Operating
Power**
210 / 420W
350 / 700W
550 /
1100W
Max. Battery
Charging Current
Rated Load Current
15A
25A
40A
25A
25A
30A
*Array voltage should never exceed this limit
**These power levels refer to the maximum wattage the PS-MPPT
can process. Higher power arrays can be used without damaging the
controller.
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ProStar MPPT Operator’s Manual
TABLE OF CONTENTS
1.0 Important Safety Instructions............................. 1
2.0 General Information..... .................................... ..10
2.1
2.2
2.3
2.4
2.5
Overview................................................................10
Regulatory Information........................................11
Versions and Ratings................................................13
Features.................................................................14
Optional Accessories..............................................16
3.0 Installation.............................................................18
3.1
3.2
3.3
3.4
General Installation Notes......................................18
Configuration.........................................................21
Mounting...............................................................24
Wiring...................................................................25
4.0 Operation..............................................................35
4.1
4.2
4.3
4.4
4.4.1
4.4.2
4.4.3
4.5
4.6
4.7
4.7.1
4.7.2
4.7.3
4.7.3.1
TrakStar MPPT Technology....................................... 35
Battery Charging Information...................................37
Load Control Information........................................ 47
LED Indications......................................... .... ....... .49
Power-up............................................................... .49
Status LED.............................................................. 49
State-of-charge LEDs...............................................50
Push-button Use in Non-Metered Version.............50
Alarms......................................................................51
Custom Settings............................. ........................53
Programming with Meter Display........................... 53
Programming in MSView.........................................54
Meter Display Operation.........................................55
Directional Key Use and Operation / Navigating
the Meter Map.......................................................55
4.7.3.2 Adjusting the Meter Display...................................55
ProStar MPPT Operator’s Manual
iii
4.7.4 Using the Meter Display to Program Charging
Set-points, Load Control, Communications, and
Advanced Settings....................................................55
4.7.5 Lighting Control / Programming Overview...............55
4.7.6 Lighting Programming Using Meter Display.............56
4.8
Inspection and Maintenance..................................... 57
5.0 Troubleshooting...........................................59
5.1
5.2
LED Fault Indications.................................................. .59
Battery Charging and Performance Issues..................64
6.0 Warranty and Policies..................................65
7.0 Technical Specifications............................... 69
Appendix A - Efficiency.........................................72
Appendix B - De-rating Graphs.......................... 74
Appendix C - Wire Sizing Charts............................ 75
8.0 Certifications............................................... 81
iv
ProStar MPPT Operator’s Manual
IMPORTANT SAFETY INSTRUCTIONS
1.0
1.0
SAVE THESE INSTRUCTIONS.
This manual contains important safety, installation, operating
and mantenance instructions for the ProStar MPPT solar
controller.
The following symbols are used throughout this manual to
indicate potentially dangerous conditions or mark important
safety instructions:
WARNING: Indicates a potentially dangerous
condition. Use extreme caution when performing this
task.
CAUTION: Indicates a critical procedure for safe and
proper operation of the controller.
NOTE: Indicates a procedure or function that is
important to the safe and proper operation of the
controller.
CONSIGNES IMPORTANTES DE SÉCURITÉ
CONSERVEZ CES INSTRUCTIONS:
Ce manuel contient des instructions importantes de sécurité,
d’installations et d’utilisation du contrôleur solaire ProStar
MPPT.
Les symboles suivants sont utilisés dans ce manuel pour
indiquer des conditions potentiellement dangereuses ou des
consignes importantes de sécurité.
AVERTISSEMENT: Indique une condition potentiellement
dangereuse. Faites preuve d’une prudence extrême lors
de la réalisation de cette tâche.
PRUDENCE: Indique une procédure critique pour
l’utilisation sûre et correcte du contrôleur.
REMARQUE: Indique une procédure ou fonction
importante pour l’utilisation sûre et correcte du
contrôleur.
ProStar MPPT Operator’s Manual
1
Safety Information
• Read all of the instructions and cautions in the manual
before beginning installation.
• There are no user serviceable parts inside the
ProStar MPPT. Do not disassemble or attempt to repair
the controller.
WARNING: Risk Of Electrical Shock.
NO POWER OR ACCESSORY TERMINALS ARE
ELECTRICALLY ISOLATED FROM DC INPUT, AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN FAULT CONDITIONS, BATTERY COULD BECOME OVERCHARGED. TEST BETWEEN ALL TERMINALS AND GROUND
BEFORE TOUCHING.
• External solar and battery disconnects are required.
• Disconnect all sources of power to the controller before
installing or adjusting the ProStar MPPT.
• There are no fuses or disconnects inside the ProStar MPPT
Do not attempt to repair.
Informations de Sécurité
• Lisez toutes les instructions et les avertissements figurant
dans le manuel avant de commencer l’installation.
• Le ProStar MPPT ne contient aucune pièce réparable par
l’utilisateur. Ne démontez pas ni ne tentez de réparer le
contrôleur.
AVERTISSEMENT: Risque De Choc Électrique.
NON ALIMENTATION OU AUX BORNES
D'ACCESSOIRES SONT ISOLÉS ÉLECTRIQUEMENT DE
L'ENTRÉE DE C.C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION DANGEREUSE SOLAIRE. SOUS CERTAINES CONDITIONS
DE DÉFAILLANCE, LA BATTERIE POURRAIT DEVENIR TROP
CHARGÉE. TEST ENTRE TOUTES LES BORNES ET LA MASSE
AVANT DE TOUCHER.
2
Important Safety Instructions
• Déconnectez toutes les sources d’alimentation du contrôleur avant d’installer ou de régler le ProStar MPPT.
• Le TriStar MPPT ne contient aucun fusible ou interrupteur.
Ne tentez pas de réparer.
• Installez des fusibles/coupe-circuits externes selon le
besoin.
Installation Safety Precautions
WARNING: This unit is not provided with a GFDI device.
This charge controller must be used with an external
GFDI device as required by the Article 690 of the
National Electrical Code for the installation location.
• Mount the ProStar MPPT indoors. Prevent exposure to the
elements and do not 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 with batteries.
• Avoid wearing jewelry during installation.
• The battery bank must be comprised of batteries of same
type, make, and age.
• UL/IEC 62109 certified for use in negative ground or
floating systems only
• Do not smoke near the battery bank.
• Power connections must remain tight to avoid excessive
heating from a loose connection.
• Use properly sized conductors and circuit interrupters.
• The grounding terminal is located in the case, and is
identified by the symbol below:
ProStar MPPT Operator’s Manual
3
1.0
• External solaire et la batterie se déconnecte sont nécessaires.
Ground Symbol
• This charge controller is to be connected to DC circuits
only. These DC connections are identified by the symbol
below:
Direct Current Symbol
The ProStar MPPT controller must be installed by a qualified
technician in accordance with the electrical regulations of
the country of installation.
A means of disconnecting all power supply poles must be
provided. These disconnects must be incorporated in the
fixed wiring.
The ProStar MPPT negative power terminals are common,
and must be grounded as instructions, local codes, and
regulations require.
A permanent, reliable earth ground must be established
with connection to the ProStar MPPT ground terminal.
The grounding conductor must be secured against any
accidental detachment.
Précautions de Sécurité D’installation
AVERTISSEMENT: L’appareil n’est pas fourni avec un
dispositif GFDI. Ce contrôleur de charge doit être
utilisé avec un dispositif GFDI externe tel que requis
par l’Article 690 du Code électrique national de
l’emplacement de l’installation.
4
Important Safety Instructions
1.0
• Montez le ProStar MPPT à l’intérieur. Empêchez
l’exposition aux éléments et la pénétration d’eau dans le
contrôleur.
• Installez le MPPT ProStar dans un endroit qui empêche
le contact occasionnel. Le dissipateur de chaleur ProStar MPPT peut devenir très chaud pendant le fonctionnement.
• Utilisez des outils isolés pour travailler avec les batteries.
• Évitez le port de bijoux pendant l’installation.
• Le groupe de batteries doit être constitué de batteries du
même type, fabricant et âge.
• UL/IEC 62109 certifié pour utilisation au négatif à la
masse ou les systèmes flottants seulement.
• Ne fumez pas à proximité du groupe de batteries.
• Les connexions d’alimentation doivent rester serrées
pour éviter une surchauffe excessive d’une connexion
desserrée.
• Utilisez des conducteurs et des coupe-circuits de dimensions adaptées.
• La borne de mise à la terre se trouve dans l'affaire et est
identifié par le symbole ci-dessous :
• Ce contrôleur de charge ne doit être connecté qu’à
des circuits en courant continu. Ces connexions CC sont
identifiées par le symbole ci-dessous:
ProStar MPPT Operator’s Manual
5
Le régulateur MPPT ProStar doit être installé par un
technicien qualifié conformément aux règlements du pays
d'installation électriques.
Un moyen de déconnexion de tous les poteaux
d'alimentation doit être fourni. Ceux-ci se déconnecte doit
être intégrée dans le câblage fixe.
Une mise à la terre permanent et fiable s'impose avec
raccordement à la borne ProStar MPPT.
Les bornes de puissance négative ProStar MPPT sont communs et doivent être mise à la terre comme les directives, les
codes locaux, et les règlements exigent.
Le conducteur de terre doit être protégée contre tout détachement accidentel.
Battery Safety
WARNING: A battery can present a risk of electrical
shock or burn from large amounts of short-circuit current, fire, or explosion from vented gases.
Observe proper precautions.
6
AVERTISSEMENT: Une batterie peut présenter a ris
que de choc électrique ou de brûlure de grandes
quantités de court-circuit curlouer, incendie ou
explosion de ventilé gaz. Observer précautions
appropriées.
WARNING: 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 est nécessaire. Ne pas jeter les piles dans le feu. Se référer aux réglementations locales ou des codes pour les exigences.
CAUTION: When replacing batteries, use properly
specified number, sizes, types, and ratings based on
application and system design.
Important Safety Instructions
PRUDENCE: Lorsque le remplacement des piles, utilisez correctement nombre spécifié, tailles, types et les évaluations basées sur conception de système et d'application.
CAUTION: Do not open or mutilate batteries.
Released electrolyte is harmful to skin, and may be toxic.
PRUDENCE: Ne pas ouvrir ou mutiler les piles.
L'électrolyte est nocif pour la peau et peut être
toxique.
• Servicing of batteries should be performed, or supervised,
by personnel knowledgeable about batteries, and the
proper safety precautions.
• Be very careful when working with large lead-acid
batteries. Wear eye protection and have fresh water
available in case there is contact with the battery acid.
• Remove watches, rings, jewelry and other metal objects
before working with batteries.
• Wear rubber gloves and boots
• Use tools with insulated handles and avoid placing tools
or metal objects on top of batteries.
• Disconnect charging source prior to connecting or
dis-connecting battery terminals.
• Determine if battery is inadvertently grounded. If so,
remove the source of contact with ground. Contact with
any part of a grounded battery can result in electrical
shock. The likelihood of such a shock can be reduced
if battery grounds are removed during installation and
maint​enance (applicable to equipment and remote
battery supplies not having a grounded supply circuit).
• Carefully read the battery manufacturer's instructions
before installing / connecting to, or removing batteries
from, the ProStar MPPT.
• Be very careful not to short circuit the cables connected
to the battery.
• Have someone nearby to assist in case of an accident.
• Explosive battery gases can be present during charging.
Be certain there is enough ventilation to release the
gases.
ProStar MPPT Operator’s Manual
7
1.0
• Never smoke in the battery area.
• If battery acid comes into contact with the skin, wash
with soap and water. If the acid contacts the eye, flood
with fresh water and get medical attention.
• Be sure the battery electrolyte level is correct before starting
charging. Do not attempt to charge a frozen battery.
• Recycle the battery when it is replaced.
• Entretien des batteries devrait être effectué ou supervisé,
par un personnel bien informé sur les piles et les précautions de sécurité appropriées.
• Soyez très prudent quand vous travaillez avec des
grandes batteries au plomb. Portez des lunettes de protection et ayez de l’eau fraîche à disposition en cas de
contact avec l’électrolyte.
• Enlevez les montres, bagues, bijoux et autres objets mé
talliques avant de travailler avec des piles.
• Porter des bottes et des gants de caoutchouc
• Utiliser des outils avec poignées isolantes et évitez de
placer des outils ou des objets métalliques sur le dessus
de batteries.
• Débrancher la source de charge avant de brancher ou
dis-reliant les bornes de la batterie.
• Utilisez des outils isolés et évitez de placer des objets
métalliques dans la zone de travail.
• Déterminer si batterie repose par inadvertance. Dans
l'affirmative, supprimer la source du contact avec le sol.
Contact avec n'importe quelle partie d'une batterie mise
à la terre peut entraîner un choc électrique. La probabilité
d'un tel choc peut être réduite si des motifs de batterie
sont supprimés pendant l'installation et maintentretien
(applicable à l'équipement et les fournitures de pile de la
télécommande n'ayant ne pas un circuit d'alimentation
mise à la terre).
8
Important Safety Instructions
• En cas de contact de l’électrolyte avec la peau, lavez avec
du savon et de l’eau. En cas de contact de l’électrolyte
avec les yeux, rincez abondamment avec de l’eau fraîche
et consultez un médecin.
• Assurez-vous que le niveau d’électrolyte de la batterie est
correct avant de commencer la charge. Ne tentez pas de
charger une batterie gelée.
• Recyclez la batterie quand elle est remplacée.
ProStar MPPT Operator’s Manual
9
1.0
• Lisez attentivement les instructions du fabricant de la
batterie avant d'installer / connexion à ou retrait des
batteries du ProStar MPPT.
• Veillez à ne pas court-circuiter les câbles connectés à la
batterie.
• Ayez une personne à proximité qui puisse aider en cas
d’accident.
• Des gaz explosifs de batterie peuvent être présents pendant la charge. Assurez-vous qu’une ventilation suffisante
évacue les gaz.
• Ne fumez jamais dans la zone des batteries
2.0
GENERAL INFORMATION
2.1 Overview
Thank you for choosing the ProStar MPPT charge controller
with TrakStarTM MPPT Technology. The ProStar MPPT is an
advanced maximum power point tracking solar battery charger. The controller features a smart tracking algorithm that
finds and maintains operation at the power source's peak
power point, maximizing energy harvest.
The ProStar MPPT battery charging process has been
optimized for long battery life and improved system performance. Self-diagnostics and electronic error protections
prevent damage when installation mistakes or system faults
occur. The controller also features eight (8) adjustable settings switches, several communication ports, and terminals
for remote battery temperature and voltage measurement.
Please take the time to read this operator’s manual to
become familiar the many benefits the ProStar MPPT can
provide for your PV systems, for example:
• Rated for 12 or 24 volt systems, and 25 or 40 amps of
charging current
• Fully protected with automatic and manual recovery
• Seven standard charging programs selectable with DIP
switches
• Continuous self-testing with fault notification
• LED indications and push-button or meter key functions
• Terminals sized for #2 AWG (35mm2) wire - compliant
when used with the optional Morningstar Wire Box,
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)
10
General Information
2.2 Regulatory Information
NOTE: This section contains important
information for safety and regulatory
requirements.
(2) this device must accept any interference
received, including interference that may cause
undesired operation.
Changes or modifications not expressly approved
by Morningstar for compliance could void the user’s
authority to operate the equipment.
NOTE: This equipment has been tested and found
to comply with the limits for a Class B digital
device, pursuant to Part 15 of the FCC rules. These limits
are designed to provide reasonable protection against
harmful interference in a residential installation. This
equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful
interference to radio communication. However, there is no
guarantee that interference will not occur in a particular
installation.
If this equipment does cause harmful interference to radio
or television reception, which can be determined by
turning the equipment on and off, the user is encouraged
to try to correct the interference by one or more of the
following measures:
• Re-orient or relocate the receiving antenna.
• Increase the separation between the equipment and
receiver.
ProStar MPPT Operator’s Manual
11
2.0
FCC requirements:
This device complies with Part 15 of the FCC rules.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference,
and,
• Connect the equipment into an outlet on a circuit
different from that to which the receiver is connected.
• Consult the dealer, or an experienced radio/TV
technician for help.
This Class B digital apparatus complies with Canadian
ICES-003.
Cet appareil numerique de la classe B est conforme a la
norme NMB-003 du Canada.
12
General Information
2.3 Versions and Ratings
2.0
PS-MPPT-25
• Rated for maximum 25 amps continuous current
(battery or load)
• Designed for 12 or 24 VDC systems
PS-MPPT-25M
• Includes metering display
• Rated for maximum 25 amps continuous current (battery
or load)
• Designed for 12 or 24 VDC systems
PS-MPPT-40
• Rated for maximum 40 amps of continuous battery current
and 30 amps of continuous load current
• Designed for 12 or 24 VDC systems
PS-MPPT-40M
• Includes metering display
• Rated for maximum 40 amps continuous battery current
and 30 amps of continuous load current
• Designed for 12 or 24 VDC systems
ProStar MPPT Operator’s Manual
13
2.4 Features
The features of the ProStar MPPT are shown in Figure 2-1
below. An explanation of each feature is provided.
8
1
2
9
3
10
4
11
12
13
5
6
14
7
15
16
Figure 2-1. PS-MPPT Features
14
General Information
1 - Charging Status / Error LED
Shows charging current and error condition statuses.
2 - Heatsink
Aluminum heatsink (underneath) to dissipate controller heat (the
ProStar MPPT is 100% passively cooled for reliability)
2.0
3 - Meter Display
Digital LCD monitoring and programming display
4 - Battery Status / Fault LED Indicators
Three state of charge (SOC) LED indicators show charging status and
controller faults
5 - Solar Positive and Negative Terminals
Power connections for Solar (+) and (-) cable terminations
6 - Load Positive and Negative Terminals
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 on ambient temperature (not used if Remote Temperature Sensor is connected)
9 - Meter Directional Buttons
Used to navigate throughout meter map
10 - DIP Switches
Eight (8) settings switches to configure operation of the ProStar MPPT
11 - MeterBusTM Port
RJ-11 socket for Morningstar MeterBusTM network connections
12 - Grounding Terminal
A chassis ground terminal for system grounding
13 - Battery Sense Terminals
Connection points for battery voltage sensing wires
14 - Remote Temperature Sensor Terminals (RTS)
Connection points for a Morningstar RTS to remotely monitor battery
temperature
15 - Wire Box for ProStar-MPPT
Optional accessory to route wiring through knock-outs
16 - Wire Box for ProStar-MPPT Knock-outs
Knock-outs for routing wires to conduit or wire gland terminations
ProStar MPPT Operator’s Manual
15
2.5 Optional Accessories
The following accessories are available for purchase
separately from your authorized Morningstar dealer:
Remote Temperature Sensor (Model: RTS)
The RTS measures battery temperature for accurate temperature compensation and is recommended when the ambient battery temperature differs from the ambient controller
temperature by more than 5º C. The standard cable length
is 33 ft (10m).
NOTE: The use of a Remote Temperature Sensor is
strongly recommended. Controller location, air flow, and
system power can drastically affect the local temperature sensor
reading. An RTS will provide optimal charging performance.
RM-1 Meter
The digital Remote Meter displays system operating information, error indications, and self-diagnostic read-out.
Information is displayed on a backlit 4-digit custom LCD display. The large numerical display and icons are easy to read
and large buttons make navigating the meter menus easy.
Additionally, a status LED and three (3) battery SOC LEDs
provide system status at a glance.
The meter can be flush mounted in a wall or surface
mounted using the mounting frame (included). The RM-1 is
supplied with 33 ft (10.0 m) of cable, a mounting frame, and
mounting screws. The RM-1 connects to the RJ- 11 Meter
port on the ProStar MPPT.
RelayDriver (RD-1)
The Relay DriverTM accessory enables the ProStar MPPT to
control external devices. Four (4) relay control ports can be
configured (in various combinations) to perform the
following tasks:
• generator control (2, 3, and 4-wire configurations)
• dry contacts for alarms and other signals
• advanced load control
16
General Information
• vent fan control
• DIN rail compatible or surface mount
2.0
Ground-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 wiring box that can be added to any version of
ProStar MPPT controller. The box acts as a junction (using
knock-outs) to run controller wiring to external conduit, if
desired. The wire box cannot be used with rigid conduit.
The communications accessories / adaptors below should
be housed in the Wire Box for ProStar MPPT.
Communications Support:
Ethernet Communications Adapter (EMC-1)
This product is an Ethernet gateway that provides web
monitoring services, a Modbus TCP/IP server, and a local web
page server. End users can collect information about their offgrid PV system remotely. One EMC-1 supports all products
with MeterBus ports by bridging MODBUS TCP/IP requests
to serve LiveView pages for each product.
USB Communications Adapter (UMC-1)
A modular unit that uses a USB-B plug, usually from a USB
A-B computer cable, and an RJ-11 plug to connect with a
Morningstar controller's MeterBus port, for monitoring and
programming using MSView PC software.
PC MeterBus AdapterTM (Model: MSC)
The MSC converts the MeterBus RJ-11 electrical
interface to an isolated standard RS-232 interface which
enables communication between the ProStar MPPT and a
personal computer (PC). The MSC is required for programming custom charging set-points, and for logging data. See
Section 4.7 for information on programming.
ProStar MPPT Operator’s Manual
17
3.0
INSTALLATION INSTRUCTIONS
3.1 General Installation Notes
• Read through the entire installation section first before beginning installation.
• Be very careful when working with batteries. Wear eye protection. Have fresh water available to wash and clean any contact with battery acid.
• Use insulated tools and avoid placing metal objects near the batteries.
WARNING: Equipment Damage or Risk of
Explosion
Never install the ProStar MPPT in an enclosure
with vented/flooded batteries. Battery fumes
are flammable and will corrode and destroy the
ProStar MPPT circuits.
CAUTION: Equipment Damage
When installing the ProStar MPPT in an enclosure,
ensure sufficient ventilation. Installation in a
sealed enclosure will lead to over-heating and a
decreased product lifetime.
AVERTISSEMENT: Endommagement de
l’équipement ou risque d’explosion
N’installez jamais le ProStar MPPT dans une
enceinte avec des batteries à évent/à électrolyte
liquide. Les vapeurs des batteries sont
inflammables et corroderont et détruiront les
circuits du ProStar MPPT.
PRUDENCE: Endommagement de l’équipement
Assurez une ventilation suffisante en cas
d’installation du ProStar MPPT9 dans une enceinte.
L’installation dans une enceinte hermétique
entraîne une surchauffe et une réduction de la
durée de vie du produit.
18
Installation Instructions
• The ProStar MPPT is designed to regulate ONLY solar
(photovoltaic) power. Connection to any other type of
power source e.g. wind turbine or generator may void
the warranty. However, other power sources can be
connected directly to the battery.
• With the standard terminal cover, the maximum wire
size is #6 AWG / 16 mm2 (solid/multi-strand) or #8
AWG / 10 mm2 (fine strand). When using the Wire Box
accessory, the maximum wire size is #2 AWG. Use a
flathead insulated screwdriver, and torque tightly up to
35 in-lb.
ProStar MPPT Operator’s Manual
19
3.0
• Do not install in locations where water can enter the
controller.
• Loose power connections and /or corroded wires may result in resistive connections 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.
• Preset charging profiles are generally designed for
lead acid batteries. Custom settings can be used for
varied charging requirements (see sections 3.2 and 4.7
for details). Note that some battery types may not be
compatible.
• The ProStar MPPT battery connection may be wired
to one battery, or a bank of batteries. The following
instructions refer to a singular battery, but it is implied
that the battery connection can be made to either one
battery or a group of batteries in a battery bank.
• The ProStar MPPT uses stainless steel fasteners,
an anodized aluminum heat sink, and conformal
coating to protect it from harsh conditions. However,
for acceptable service life, extreme temperatures and
marine environments should be avoided.
• The ProStar MPPT prevents reverse current leakage at
night, so a blocking diode is not required in the system.
• Stranded wires to be connected to the ProStar MPPT
terminals should be prepared first with e.g. clamped
copper heads, etc. to avoid the possibility of one
conductor free out of the connection screw, and
possible contact with the metal enclosure.
WARNING: Solar and battery fuses or DC breakers
are required in the system. These protection devices
are external to the ProStar MPPT controller, and must be a
maximum of 30 amps for the PS-MPPT-25/M and 50 amps
for the PS-MPPT-40/M.
AVERTISSEMENT: Solaire et batterie fusibles ou
disjoncteurs DC sont nécessaires dans le système.
Ces dispositifs de protection sont externes au contrôleur
MPPT ProStar et doivent être un maximum de 30 ampères
pour le PS-MPPT-25/M et 50 ampères pour le PS-MPPT40/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 exceed any
specific wire ampacity.
AVERTISSEMENT: Installation doit être conforme à
toutes les requirments US National Electrical Code
et Code Canadien d'Electricité. Disjoncteurs et fusibles
peuvent exiger des cotes inférieures que mentionnés cidessus de manière à ne pas pour dépasser n'importe quel
fils particulier admissible.
.
WARNING: Minimum over-current protection
device interrupt ratings must be 2000A for 12V
systems, and 4000A for 24V systems.
AVERTISSEMENT: Protection contre les
surintensités minimum cotes d'interruption de
périphérique doivent être de 2000 a 12V systèmes et 4000 a
pour les systèmes de 24V.
20
Installation Instructions
3.2 Configuration
The DIP switch block shown in Figure 3.1 below is used to
set the operating parameters for the ProStar MPPT.
3.0
Figure 3.1. DIP Switch Block to set charging parameters
Switch 1: Load / Lighting
Mode
Switch 1
Normal
OFF
Lighting
ON
Switches 2, 3: System Voltage
Three (3) system voltage configurations are available as
shown in the table below:
System Voltage
Switch 2
Switch 3
Auto
OFF
OFF
12
OFF
ON
24
ON
OFF
ProStar MPPT Operator’s Manual
21
NOTE: Before connecting the battery, measure the open-circuit
voltage. It must be over 10 volts to start the controller. If the
system voltage Settings Switches are set to Auto-detect, battery
voltage over 15.5V will be detected as a 24V nominal battery,
and the unit will charge accordingly. The 12/24V auto selection is
only done at start-up, and the detected system voltage will never
change during operation.
Generally, the specfic system voltage is known, and it is best
to set DIPs 2,3 accordingly; the auto-detect setting should
be used only in rare circumstances.
Switches 4, 5, 6: Battery Type Selection
Preset ProStar MPPT battery charging options are shown in
table 3-1 below. All voltage settings listed are for nominal
12 volt batteries.
Multiply the voltage settings by two (2) for 24 volt systems.
NOTE: These settings are general guidelines for
use at the operator’s discretion. The ProStar MPPT
can be programmed to satisfy a wide range of charging parameters, but only the battery manufacturer can recommend optimal
settings for their products.
DIP
Switch
Settings
4-5-6
Absorp.
Stage
(volts)
Float
Stage
(volts)
off-off-off 1 - Sealed*
14.00
13.70
off-off-on 2 - Sealed*
14.15
13.70
14.40
off-on-off 3 - Sealed*
14.30
13.70
14.65
off-on-on
Battery
Type
4- AGM/Flooded
Equalize
Stage
(volts)
Absorp.
Time
(mins)
Equalize
Time
(mins)
Equalize
Timeout
(mins)
Equalize
Interval
(days)
150
60
120
28
150
60
120
28
150
14.40
13.70
15.10
180
120
180
28
on-off-off 5 - Flooded
14.60
13.50
15.30
180
120
180
28
on-off-on
6 - Flooded
14.70
13.50
15.40
180
180
240
28
on-on-off
7 - L-16
on-on-on
8 - Custom
15.40
13.40
16.00
180
180
240
14
Custom
Custom
Custom
Custom
Custom
Custom
Custom
“Sealed” battery
type includes
gel and AGM
batteries
**“Sealed”
battery
type includes
gel
and AGM batteries
Table 3.1. Battery charging settings for each selectable battery type
22
Installation Instructions
Switch 7: Battery Equalization
Mode
Switch 7
Manual Equalization
OFF
Auto Equalization
ON
Switch 8: Meterbus / MODBUS Settings
Switch 8
Meterbus
OFF
MODBUS
ON
ProStar MPPT Operator’s Manual
3.0
Mode
23
3.3 Mounting
Inspect the controller for shipping damage. Mount the
ProStar MPPT to a vertical surface (4-#8 stainless steel
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: The heat sink must be in a vertical position (fins
up and down).
For proper air flow, allow at least 15 cm (6 in) of space
above and below the controller, and 50 mm (2 in) at the
sides - see Figure 3-2 below. Install in an area protected
from direct rain and sun.
If the controller is installed in an enclosure, some
ventilation is recommended. Do not locate in an enclosure
where battery gases can accumulate.
6 in / 150 mm
2 in /
50 mm
6 in / 150 mm
Figure 3-2. Proper Clearances for Passive Cooling
24
Installation Instructions
3.4 Wiring
3.0
SS+-
3
S-
S+
7
L-
L+
5
B+
2
B-
4
6
To battery (+) and
(-) terminals for
voltage sensing
1
To properly
sized array
To load (+)
and (-)
terminals
To battery (+)
and (-)
terminals
To battery for
temperature
sensing
Figure 3-3. Wiring the PS-MPPT
REFER TO FIGURE 3.3 WHEN USING THE WIRING INSTRUCTIONS
BELOW.
NOTE: THE PS-MPPT IS UL 1741 COMPLIANT WHEN USED WITH THE OPTIONAL WIRE BOX. THE WIRE BOX CANNOT
BE USED WITH RIGID CONDUIT. THE PS-MPPT IS UL RECOGNIZED
FOR USE IN A UL LISTED ASSEMBLEY WITHOUT THE WIRE BOX FOR
THE PS-MPPT.
ProStar MPPT Operator’s Manual
25
STEP 1: Check Controller Limitations
Verify that the highest temperature compensated solar array
open-circuit voltage (Voc), and load current do not exceed
the ratings of the ProStar MPPT version being installed.
Multiple controllers can be installed in parallel on the same
battery bank to achieve greater total charging current. In
this type of system, each ProStar MPPT must have its own
solar array. The load terminals of multiple controllers can
only be wired together if the total load draw does not exceed the nameplate current of the LOWEST rated controller.
STEP 2: Battery Voltage Sense Wires
Due to connection and cable resistance, voltage drops are
unavoidable in power cables that carry current, including the
ProStar MPPT battery cables. If Battery Sense wires are not
used, the controller must use the voltage reading at the battery power terminals for regulation. This voltage may differ
from the actual battery bank voltage due to voltage drop.
Battery Voltage Sense is a high impedance connection that
enables the ProStar MPPT to measure the battery terminal voltage precisely with small gauge wires that have no
voltage drop. When connected directly to the battery, the
sense wires will improve battery charging accuracy. Battery
voltage sense wires are recommended 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 wiring with 2% drop can result in a 0.3 volt drop for
14.4V charging. Voltage drops will cause some undercharging of the battery. The controller will begin Absorption or
limit equalization at a lower battery voltage because the
controller measures a higher voltage at the controller’s terminals than is the actual battery voltage. For example, if the
controller is programmed to start Absorption at 14.4V, when
the controller "sees" 14.4 volts at its battery terminals,
26
Installation Instructions
the true battery voltage would only be 14.1 volts, if there is
a 0.3 volt drop between the controller and battery.
Note that the battery sense wires will not power the
controller, and the sense wires will not compensate for
losses in the power wires between the controller and the
battery. The battery sense wires are used to improve the
accuracy of the battery charging.
Observing correct polarity, connect both battery voltage
sense wires to the ProStar MPPT at the 2-position Battery
Sense terminal, and to battery (+) and (-) terminals. No
damage will occur if the polarity is reversed, but the controller cannot read a reversed sense voltage.
Tighten the connector screws to 5 in-lb (0.56 Nm) of torque.
The maximum length allowed for each battery voltage sense
wire is 98 ft (30 m).
Connecting the voltage sense wires to the RTS terminal will
cause an alarm.
NOTE: If the battery input voltage is greater than 5 volts
different than the Battery Sense, due to voltage drops or
faulty connections, the Battery Sense input will not be recognized
by the ProStar MPPT.
A battery voltage sense connection is not required to
operate the ProStar MPPT controller, but it is recommended
for best performance.
ProStar MPPT Operator’s Manual
27
3.0
The two sense wires, can range in size from 1.0 to 0.25 mm2
(16 to 24 AWG), and should be cut to length as required
to connect the battery to the voltage sense terminals. A
2-position terminal (see figure 3.3) is used for the battery
sense connection. A twisted pair cable is recommended but
not required. Use UL rated 300 Volt conductors. The voltage
sense wires may be pulled through conduit with the power
conductors.
STEP 3: Remote Temperature Sensor
WARNING: Risk of Fire.
If no Remote Temperature Sensor (RTS) is connected,
use the ProStar MPPT within 3m (10 ft) of the batteries. Internal
Temperature Compensation will be used if the RTS is not connected. Use of the RTS is strongly recommended.
AVERTISSEMENT: Risque d'incendie.
Si non Capteur de température distant (RTS) est connecté, utilisez le MPPT ProStar moins de 3m (10 pi) de les batteries.
Compensation de la température interne sera utilisée si la RTS
n'est pas connecté. Utilisation de la RTS est fortement recommandé.
All charging settings are based on 25°C (77°F). If the
battery temperature varies by 5°C, the charging setting will
change by 0.15 Volts for a 12 Volt battery. This is a substantial change in the charging of the battery, and the use of the
optional Remote Temperature Sensor (RTS) is recommended
to adjust charging to the actual battery temperature. The
RTS can be added at any time after the system has been
installed.
Connect the RTS to the 2-position terminal located 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 screw terminal. The RTS cable may
be pulled through conduit along with the power wires.
Tighten the connector screws to 5 in-lb (0.56 Nm) of torque.
Separate installation instructions are provided inside the RTS
bag.
WARNING: Equipment Damage
Never place the temperature sensor inside a battery cell. Both the RTS and the battery will be damaged.
AVERTISSEMENT: Endommagement de l’équipement
Ne placez jamais la sonde de température dans un
élément de batterie. Le RTS et la batterie seraient endommagés.
28
Installation Instructions
CAUTION: The ProStar MPPT will use the local
temperature sensor for compensation if the RTS is not
used.
PRUDENCE: Le TriStar MPPT ne compense pas la
température des paramètres de charges si le RTS n’est
pas utilisé.
REMARQUE: Le câble de RTS peut être raccourci
si la totalité de la longueur n’est pas nécessaire.
Assurez-vous de réinstaller la bobine en ferrite sur l’extrémité du
RTS si une longueur de câble est enlevée. Cette bobine assure la
conformité avec les normes d’émissions électromagnétiques.
STEP 4: Grounding and Ground Fault Interruption
WARNING:
This unit is not provided with a GFDI device. This
charge controller must be used with an external GFDI
device as required by the Article 690 of the National
Electrical Code for the installation location.
NOTE:
Conductors identified by the color combination green/
yellow shall only be used for earthing conductors.
AVERTISSEMENT :
L’appareil n’est pas fourni avec un dispositif GFDI. Ce
contrôleur de charge doit être utilisé avec un dispositif
GFDI externe tel que requis par l’Article 690 du Code
électrique national de la région de l’installation.
Use a copper wire to connect the grounding terminal in the
case to earth ground. The grounding terminal is identified
by the ground symbol on the case, just above the terminal,
as shown below.
ProStar MPPT Operator’s Manual
29
3.0
NOTE: The RTS cable may be shortened if the
full length is not needed. Be sure to reinstall the ferrite
choke on the end of the RTS if a length of cable is removed.
This choke ensures compliance with electromagnetic emissions
standards.
Figure 3-4. Ground Symbol
WARNING: Risk of Fire
DO NOT bond system electrical negative to earth
ground at the controller. Per NEC requirements, system
negative must be bonded to earth ground through a
GFPD at only one point.
AVERTISSEMENT : Risque d’incendie
NE LIEZ PAS le côté négatif du système à la mise à la
terre au niveau du contrôleur. Selon les exigences du
CNE, le côté négatif du système doit être mis à la terre
par un GFPD à un seul point.
Do not connect the system negative conductor to the
terminal. NEC requires the use of an external ground fault
protection device (GFPD). The ProStar MPPT does not have
internal ground fault protection. The system electrical negative should be bonded through a GFPD to earth ground at
one (and only one) location. The grounding point may be
located in the solar, or the battery circuit.
Per NEC 690.45 (A) and NEC Table 250.122, minimum sizes
for copper grounding wire are:
• ProStar MPPT-25 10 AWG (5 mm2)
• ProStar MPPT-40 10 AWG (5 mm2)
OR, of the same, or greater, cross-sectional area as the PV
wires.
30
Installation Instructions
3.0
STEP 5: Load Connections
Turn the loads off, and connect the load wires to the load
terminals. DO NOT CLOSE BREAKER AT THIS TIME.
BATTERY (+)
BATTERY (-)
30 or 50 Amp
Breaker - depending
on model
6 in (150 mm)
MAX.
+
-
12V / 24V
BATTERY
EARTH
GROUND
ProStar MPPT Operator’s Manual
31
STEP 6: Battery Connections
Be sure that DIP switches 2 and 3 are set for 12 or 24V, as
described in Section 3.2
NOTE: Before connecting the battery, measure the open-circuit
voltage. It must be over 10 volts to start the controller. If the
system voltage Settings Switches are set to Auto-detect, battery
voltage over 15.5V will be detected as a 24V nominal battery, and
the unit will charge accordingly. The 12/24V auto selection is only
done at start-up.
With the battery disconnect open, connect the battery (+)
and (-) wires from the battery to controller. DO NOT CLOSE
THE BREAKER AT THIS TIME.
120Voc Maximum
40 Volt
MODULE
40 Volt
MODULE
40 Volt
MODULE
SOLAR (+)
Solar
Disconnect
(- )
(+)
(- )
(-)
(+)
EARTH
GROUND
(+)
SOLAR (-)
STEP 7: Solar Connections
WARNING: Shock Hazard
The solar PV array can produce open-circuit voltages
in excess of 120 Vdc when in sunlight. Verify that the
solar input breaker or disconnect has been opened
(disconnected) before installing the system wires.
32
Installation Instructions
AVERTISSEMENT: Risque de décharge électrique
Le réseau PV solaire peut produire des tensions de
circuit ouvert supérieures à 120 Vdc à la lumière du
soleil. Vérifiez que le coupe-circuit ou l’interrupteur
d’entrée solaire a été ouvert (déconnexion) avant
d’installer les câbles du système.
With the solar disconnect open, connect the solar (PV) array
wires to the PS-MPPT solar terminals. Use caution, since
the solar array will produce current whenever in sunlight.
A solar disconnnect is a convenient way to break the PV
connection when necessary.
STEP 8: Power-Up and Verify System Operation
NOTE: Carefully observe the LEDs after each connection.
The LEDs will indicate proper polarity and a good
connection.
Next, the green, yellow or red LED will light depending on
the battery state-of-charge (SOC). Confirm that one of these
LEDs is on before going to the next step.
Close the solar disconnect. If the solar input is connected
while in sunlight, the charging LED indicator will light. Confirm proper connection by observing the charging LED.
Close the load disconnect, and turn the load on, to confirm
a proper connection.
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 blinking R/G – Y)
ProStar MPPT Operator’s Manual
33
5.0
Close the battery breaker to power on the controller. Watch
the the charging status, and then the three battery stateof-charge (SOC) LEDs blink in sequence (G-Y-R), confirming
proper start-up. If they do not light, check the battery polarity (+/–) and battery voltage.
• there is an overload condition (LEDs blinking R/Y - G)
• the load is not connected, not working, or turned off
After all connections have been completed, observe the
LEDs to make sure the controller is operating normally for
system conditions. If the optional digital meter is used,
observe that the display is scrolling with proper voltage
and current values. Also, a self- test can be performed with
digital meter units.
STEP 9: To Power-down
WARNING: Risk of Damage
ONLY disconnect the battery from the ProStar MPPT
AFTER the solar input has been dis-connected. Damage to
the controller may result if the battery is removed while the ProStar MPPT is charging.
AVERTISSEMENT:
Risque d’endommagement
Le TriStar MPPT 150V SEULEMENT déconnecter la
batterie APRÈS l’entrée solaire a été déconnectée. Le contrôleur pourrait endommager si la batterie est retirée quand
le TriStar MPPT 150V est en charge.
• To prevent damage, power-down must be done in the
reverse order as power-up.
34
Installation Instructions
4.0OPERATION
4.1 TrakStar MPPT Technology
The ProStar MPPT utilizes Morningstar’s TrakStar Maximum Power Point Tracking technology to extract maximum
power from the solar module(s). The tracking algorithm
is fully automatic and does not require user adjustment.
Trakstar technology will track the array maximum power
point voltage (Vmp) as it varies with weather conditions,
ensuring that maximum power is harvested from the array
through the course of the day.
(1) Power Into the ProStar MPPT = Power Out of the ProStar
MPPT
(2) Volts In x Amps In = Volts Out x Amps Out
* assuming 100% efficiency i.e. if no losses in wiring and
conversion existed.
If the solar module’s Vmp is greater than the battery voltage,
it follows that the battery current must be proportionally
greater than the solar input current so that input and output
power are balanced. The greater the difference between the
maximum power voltage and battery voltage, the greater
the current boost. Current boost can be substantial in
systems where the solar array is of a higher nominal voltage
than the battery as described in the next section.
ProStar MPPT Operator’s Manual
35
4.0
Current Boost:
In many cases, TrakStar MPPT technology will “boost” the
solar charge current. For example, a system may have 2
amps of solar current flowing into the ProStar MPPT and
5 amps of charge current flowing out to the battery. The
ProStar MPPT does not create current! Rest assured that the
power into the ProStar MPPT is the same as the power out
of the ProStar MPPT. Since power is the product of voltage
and current (Volts x Amps), the following is true*:
High Voltage Strings and Grid-tie Modules
Another benefit of TrakStar MPPT technology is the ability
to charge 12 or 24 volt batteries with solar arrays of higher
nominal voltages. A 12 volt battery bank can be charged
with a 12, 24, 36 or 48V nominal off-grid solar array. Certain
grid-tie solar modules may also be used as long as the solar
array open circuit voltage (Voc) rating will not exceed the
ProStar MPPT 120V maximum input voltage rating at worstcase (lowest) module temperature. The solar module documentation should provide Voc vs. temperature data.
Higher solar input voltage results in lower solar input current for a given input power. High voltage solar input strings
allow for smaller gauge solar wiring. This is especially helpful for systems with long wiring runs between the solar array
and the ProStar MPPT.
An Advantage Over Traditional Controllers
Traditional controllers connect the solar module directly
to the battery when recharging. This requires that the solar module operate in a voltage range that is below the
module’s Vmp. In a 12V system, for example, the battery
voltage may range from 10 - 15 Vdc but the module’s Vmp is
typically around 17V. Figure 4.1 shows a typical current vs.
voltage output curve for a nominal 12V off-grid module.
12 Volt Module
Current vs. Voltage
CURRENT
Maximum
Power
Point
10
15 17
TrackStar
Maximum
Power
Point
POWER
Typical Battery
Voltage Range
12 Volt Module
Output Power
Traditional
Controller
Operating Range
VOLTAGE
10
15 17
VOLTAGE
Figure 4.1. Nominal 12 volt solar module I-V curve and output power
graph
36
Operation
4.2 Battery Charging Information
4-Stage Charging
VOLTAGE
The ProStar MPPT has a 4-stage battery charging algorithm
for rapid, efficient, and safe battery charging. Figure 4-2
shows the sequence of stages.
EQUALIZE
BULK
CHARGE
4.0
NIGHT
ABSORPTION
FLOAT
NIGHT
TIME
Figure 4.2. ProStar MPPT Charging Algorithm
Bulk Charge Stage
During Bulk charging, the battery is not at 100% state of
charge and battery voltage has not yet charged to the Absorption voltage set-point. The controller will deliver 100%
of available solar power to recharge the battery.
Absorption Stage
When the battery has recharged to the Absorption voltage
set-point, constant-voltage regulation is used to maintain
battery voltage at the Absorption set-point. This prevents
heating and excessive battery gasing. The battery is
allowed to come to full state of charge at the Absorption
voltage set-point. The green SOC LED will blink once per
second during Absorption charging.
ProStar MPPT Operator’s Manual
37
The battery must remain in the Absorption charging
stage for a cumulative 120 - 150 minutes, depending on
battery type, before transition to the Float stage will occur.
However, Absorption time will be extended by 30 minutes
if the battery discharges below 12.50 volts (12V system) the
previous night.
The Absorption set-point is temperature compensated if the
RTS is connected.
Float Stage
After the battery is fully charged in the Absorption stage,
the ProStar MPPT reduces the battery voltage to the Float
voltage set-point. When the battery is fully recharged, there
can be no more chemical reactions and all the charging current is turned into heat and gasing. The float stage provides
a very low rate of maintenance charging while reducing the
heating and gasing of a fully charged battery. The purpose
of float is to protect the battery from long-term overcharge.
The green SOC LED will blink once every two (2) seconds
during Float charging.
Once in Float stage, loads can continue to draw power from
the battery. In the event that the system load(s) exceed the
solar charge current, the controller will no longer be able to
maintain the battery at the Float set-point. Should the battery voltage remain below the Float set-point for a cumulative 60 minute period, the controller will exit Float stage and
return to Bulk charging.
The Float set-point is temperature compensated if the RTS
is connected.
38
Operation
Equalization Stage
WARNING: Risk of Explosion
Equalizing vented batteries produces explosive gases.
The battery bank must be properly ventilated.
!
CAUTION: Equipment Damage
Excessive overcharging and gasing too vigorously can
damage the battery plates and cause shedding of active
material from the plates. An equalization that is too high
or for too long can be damaging. Review the requirements for the particular battery being used in your system.
AVERTISSEMENT: Risque d’explosion
Les batteries à évent et compensation produisent des gaz
explosifs. Le groupe de batteries doit être correctement
ventilé.
PRUDENCE: Endommagement de l’équipement
La compensation augmente la tension des batteries à des
niveaux pouvant endommager les charges sensibles en
CC. Vérifiez que toutes les charges du système sont
conçues pour la tension de compensation par température
avant de commencer une charge de compensation.
PRUDENCE: Endommagement de l’équipement
Une surcharge excessive et un dégagement gazeux trop
vigoureux peuvent endommager les plaques de batteries
et provoquer l’élimination du matériau actif des plaques.
Une compensation trop élevée ou trop longue peut
provoquer des dégâts. Examinez les exigences pour la
batterie particulière utilisée dans votre système.
Certain battery types benefit from a periodic boost charge
to stir the electrolyte, level the cell voltages, and complete
the chemical reactions. Equalization charging raises the
ProStar MPPT Operator’s Manual
39
4.0
!
CAUTION: Equipment Damage
Equalization increases the battery voltage to levels that
may damage sensitive DC loads. Verify all system loads
are rated for the temperature compensated Equalize
voltage before beginning an Equalization charge.
battery voltage above the standard absorption voltage so
that 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 4-1 in this section for
more details. The Equalization Time is defined as time spent
at the equalization set-point. If there is insufficient charge
current to reach the equalization voltage, the equalization
will terminate after an additional 60 minutes to avoid over
gasing or heating the battery. If the battery requires more
time in equalization, an equalize can be requested using the
TriStar Meter or push-button to continue for one or more
additional equalization cycles.
The Equalization set-point is temperature compensated if
the RTS is connected.
Why Equalize?
Routine equalization cycles are often vital to the performance and life of a battery - particularly in a solar system.
During battery discharge, sulfuric acid is consumed and
soft lead sulfate crystals form on the plates. If the battery
remains in a partially discharged condition, the soft crystals
will turn into hard crystals over time. This process, called
“lead sulfation”, causes the crystals to become harder
over time and more difficult to convert back to soft active
materials. Sulfation from chronic undercharging of the battery is the leading cause of battery failures in solar systems.
In addition to reducing the battery capacity, sulfate build-up
is the most common cause of buckling plates and cracked
grids. Deep cycle batteries are particularly susceptible to
lead sulfation.
Normal charging of the battery can convert the sulfate back
to the soft active material if the battery is fully recharged.
However, a solar battery is seldom completely recharged, so
the soft lead sulfate crystals harden over a period of time.
Only a long controlled overcharge, or equalization, at a
higher voltage can reverse the hardening of sulfate crystals.
40
Operation
Equalize a Sealed Battery?
The Battery Charging Settings table (see table 4-1 in this
section) shows two sealed battery settings with an Equalization cycles. These are minimal “boost” cycles to level
individual cells. This is not an equalization, and will not vent
gas from sealed batteries that require up to 14.4V charging (12V battery). Many VRLA batteries, including AGM and
gel, have charging requirements up to 14.4V (12V battery).
Depending on the battery manufacturer’s recommendation,
ProStar MPPT Operator’s Manual
41
4.0
When to Equalize?
The ideal frequency of equalizations depends on the
battery type (lead-calcium, lead-antimony, etc.), the depth
of discharging, battery age, temperature, and other factors.
One very broad guide is to equalize flooded batteries every
1 to 3 months or every 5 to 10 deep discharges. Some
batteries, such as the L-16 group, will need more frequent
equalizations.
The difference between the highest cell and lowest cell in a
battery can also indicate the need for an equalization. Either
the specific gravity or the cell voltage can be measured.
The battery manufacturer can recommend the specific
gravity or voltage values for your particular battery.
Preparation for Equalization
First, confirm that all of the system loads are rated for the
equalization voltage. Consider that at 0°C (32°F) the equalization voltage will reach 16.75 volts for L-16 batteries with
a temperature sensor installed. Disconnect any loads at risk
of damage due to the high input voltage.
If Hydrocaps are used, be sure to remove them before starting an equalization. Replace the Hydrocaps with standard
battery cell caps. The Hydrocaps can get very hot during an
equalization. Also, if Hydrocaps are used, the equalization
should be set for manual only (DIP switch #7 is Off).
After the equalization is finished, add distilled water to each
cell to replace gasing losses. Check that the battery plates
are covered.
the “boost” cycle for sealed cells can be disabled by setting
the equalize setting switch to manual, if required.
Battery Charge Settings
Preset ProStar MPPT battery charging options are shown in
tables 4-1 and 4-2 below. All voltage settings listed are for
nominal 12 Volt batteries. Multiply the voltage settings by
two (2) for 24 Volt batteries.
NOTE: These settings are general guidelines for
use at the operator’s discretion. The ProStar MPPT can
be programmed to satisfy a wide range of charging parameters,
but only the battery manufacturer can recommend optimal
settings for their products.
DIP
Switch
Settings
4-5-6
Battery
Type
Absorp.
Stage
(volts)
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
13.70
off-off-on 2 - Sealed*
14.15
13.70
14.40
150
60
120
28
off-on-off 3 - Sealed*
14.30
13.70
14.65
150
60
120
28
off-on-on
14.40
13.70
15.10
180
120
180
28
14.60
13.50
15.30
180
120
180
28
4- AGM/Flooded
on-off-off 5 - Flooded
150
on-off-on
6 - Flooded
14.70
13.50
15.40
180
180
240
28
on-on-off
7 - L-16
15.40
13.40
16.00
180
180
240
14
on-on-on
8 - Custom
Custom
Custom
Custom
Custom
Custom
Custom
Custom
“Sealed” battery
type types
includesinclude
gel and AGM
**"Sealed"
battery
gel batteries
and AGM batteries
Table 4.1. Battery charging settings for each selectable battery type
Shared Settings
Value
Units
Absorption Extension Voltage
12.50
volts
Absorption Extension Time
Absorption Time + 30
minutes
Float Exit Time-out
30
minutes
Float Cancel Voltage
12.30
volts
Equalize Time-out
Equalize Time + 60
minutes
-5
millivolts / °C
/ cell
Temperature Compensation Coefficient
Table 4.2. Battery settings that are shared among all battery types
42
Operation
The ProStar MPPT provides seven (7) standard battery
charging settings that are selected with the settings switches
(see Table 4.1 above). These standard charging settings
are suitable for lead-acid batteries ranging from sealed
(gel, AGM, maintenance-free) to Flooded and L-16 cells.
In addition, an eighth charging setting provides for custom
set-points using MSViewTM PC software. Table 4-1 above
summarizes the major parameters of the standard charging
settings. The shared settings in Table 4-2 are common to
all battery types. The following charging profiles graphically
illustrate the shared settings:
Absorption Extension
4.0
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
extended on the next charge cycle as shown in figure 4-3
above. 30 minutes will be added to the normal Absorption
duration.
ProStar MPPT Operator’s Manual
43
Float Time-out
Bulk
Absorption
Float
SubFloat
Bulk Absorption
Float V
60 mins.
below Float
1:00
2:00
3:00
4:00
5:00
6:00
time (hrs)
Figure 4-4. Float Exit Time-out Charging Profile
After entering Float stage, the controller will only exit Float
if the battery voltage remains below Float voltage for 60
cumulative minutes. In figure 4-4, a system load turns on at
4:00 hrs when the controller is in Float stage, runs for one
hour, and turns off at 5:00 hrs. The load current draw is larger than the charge current, causing battery voltage to drop
below Float voltage for 60 minutes. After the load turns off,
the controller returns to Bulk charging and then Absorption
stage once again. In this example, a load runs continuously
for 60 min. However, because the Float exit timer is cumulative, multiple momentary load events that pull the battery
voltage below Float voltage for a combined 60 minutes
duration will also force an exit from Float stage.
44
Operation
Float Cancel Voltage
4.0
Figure 4.5. Float Cancellation Charging Profile
If the battery bank discharges below 12.30 volts (24.60
volts @ 24 V) the previous night, Float charging stage will
be cancelled for the next charge cycle. Figure 4-5 above,
illustrates this concept. At 0:00 hrs (dawn), battery voltage
is below the Float Cancel threshold voltage. The diagram
shows where Float stage would have occurred if Float was
not canceled.
ProStar MPPT Operator’s Manual
45
Equalize Time-out
Figure 4.6. Equalize Time-out Charging Profile
The charging profile in figure 4-6 above, shows an Equalize
Timeout event. The timeout timer begins as soon as battery
voltage exceeds the Absorption voltage setpoint. If there is
insufficient charging current or system loads are too large,
the battery voltage may not reach the Equalize setpoint.
Equalize Time-out is a safety feature that prevents high
battery voltage for extended periods of time which may
damage the battery.
46
Operation
4.3 Load Control Information
The primary purpose of the load control function is to
disconnect system loads when the battery has discharged
to a low state of charge and reconnect system loads when
the battery is sufficiently recharged. System loads may be
lights, pumps, motors, DC appliances, and other electronic
devices. The total current draw of all loads must not exceed
the ProStar MPPT 25 or 30 amp maximum load rating.
CAUTION: Do not wire an AC inverter of any size to
the load terminals of the ProStar MPPT - damage to the
load control circuit may result. Wire inverters directly to the
battery or battery bank.
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
cause a premature LVD without the current compensation
feature. LVD and LVR set-points are adjusted lower per the
following table.
System Voltage
Current Compensation
12 Volt
-20 mV per amp of load
24 Volt
-40 mV per amp of load
Table 4-3. Current Compensation Values
LVD Warning:
As the battery discharges, the Battery Status LEDs will
transition from green to yellow and then from yellow to
flashing red. The flashing red indication is a warning that a
low voltage disconnect (LVD) event will occur soon.
ProStar MPPT Operator’s Manual
47
4.0
PRUDENCE: Ne pas raccorder un inverseur de toute
taille de la bornes de charge MPPT ProStar - endommage
ment de la charge contrôle est susceptible d'entraîner. Onduleurs de fil directement à la batterie ou groupe de batteries.
The amount of time between a green SOC indication and
load disconnect will depend on many factors including:
• rate of discharge (amount of load draw)
• capacity of the battery
• health of the battery
• LVD set-point
If the battery discharges to the LVD set-point the load will
disconnect and a solid red Battery Status LED indication will
be displayed.
General Load Control Notes:
Do not wire multiple ProStar MPPT load outputs together in
parallel to power DC loads with a current draw greater than
25 or 30A, depending on the ProStar MPPT model in use.
Equal current sharing cannot be assured and an over-load
condition will likely occur on one or more controllers.
Exercise caution when connecting loads with specific
polarity to a live load circuit. A reverse polarity connection
may damage the load. Always double check load
connections before applying power.
48
Operation
4.4 LED Indications
KEY:
G = green Y = yellow
R = red
G - Y - R = flashing sequencially
G/Y
= flashing together
G / Y - R = G and Y flashing together,
alternating with R flash
4.4.1. Power-up
Normal power-up: Status LED flashes G, then SOC LEDS
flash G - Y - R, then SOC LEDs indicate battery charge status
with a single battery status LED.
4.0
Failed bootload: Status LED flashes G, then SOC LEDS
flash G - Y and stop on solid Y.
4.4.2 Status LED
The Status LED indicates charging status and any existing solar input error conditions. The Status LED is on when
charging during the day and off at night. The Status LED will
flash red whenever an error condition(s) exists. Table 4.4 lists
the Status LED indications.
Color
None
Green
Red
Red
Indication
Off (with heartbeat¹)
On Solid
( with heartbeat² )
Flashing
On Solid
( with heartbeat2 )
Operating
State
Night
Charging
Error
Critical Error
¹ heartbeat indication flickers the Status LED on briefly every 5 seconds
² heartbeat indication flickers the Status LED off briefly every 5 seconds
Table 4.4. Status LED Definitions
ProStar MPPT Operator’s Manual
49
NOTES:
1) R flashing is generally a user addressable fault / error
2) R charging status LED ON with heartbeat blink OFF
every 5 secs is a critical fault that generally requires service.
See, "Solid Charging Status LED with Self-test (R-Y-G) SOC
Faults", in Section 5.1.
4.4.3 State-of-Charge LEDs
Battery SOC LED Indications are shown in Table 4-5 below:
Condition
Indication
Absorption
Float
Equalize
SOC > 13.5V
13.5V > SOC > 13.0V
13.0V > SOC > 12.5V
SOC < 12.5V
Low voltage disconnect warning
Low voltage disconnect
G flash - every sec
G flash - every 2 secs
G flash - 2 / sec
G solid
G / Y solid
Y solid
Y / R solid
R flash - every sec
R solid
Table 4.5. Battery SOC LED Indications
4.5 Push-Button Use in Non-Metered Version
The version of the ProStar MPPT without meter display features a push-button that operates as follows depending on
the DIP Switch 1 setting:
Normal Mode (DIP 1 OFF)
• One quick press and release will clear any faults or
reminders that are present
• Press and hold for 5 seconds to initiate an Equalization
(EQ), if unit is set to manual EQ.
50
Operation
Lighting Control Mode (DIP 1 ON)
• A quick press and release will clear any faults or reminders
that are present. A second quick press will then conduct
a lighting test. If no faults or reminders are present, the
initial press will conduct a lighting test. A lighting test
is used to verify correct wiring in the load circuit and/or
verify the lighting components are operational.
• If no faults or reminders are active, press and hold for 5
seconds to initiate an Equalization (EQ) if the unit is set to
manual EQ.
Reset PS-MPPT to Factory Settings
4.0
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 10 secs.
A Custom Edit Settings fault will occur. See p. 62 in Section
5 for details. The unit will then need to be re-powered to
resume normal opertation.
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 ProStar MPPT is designed
to operate at full rated current at the maximum ambient
temperature. This alarm indicates that there is insufficient
ProStar MPPT Operator’s Manual
51
airflow and that the heatsink temperature is approaching
unsafe limits. If the controller frequently reports this alarm
condition, corrective action must be taken to provide better
air flow or to relocate the controller to a cooler spot.
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
A battery sense wire is disconnected. Inspect the battery
sense connections. This alarm is set when the voltage at the
battery sense voltage differs by more than 5 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.
52
Operation
4.7 Custom Settings
4.7.1 Programming with the Meter Display
The ProStar MPPT is available in metered and non-metered
versions. The metered model allows:
• Custom programming, including lighting programs,
directly from the unit.
• Extensive settings adjustment and information as shown
partially in Figure 4-7 below:
Display Screens and Programming
Models:
PS-MPPT-25M
PS- MPPT- 40M
4.0
Main Screens
Solar Current - Battery
Current - Load Current
Daily Charging Stage - Time
Daily Charge Transferred Battery and Load
Daily Max / Min
Battery Voltages
COMMANDS
Clear Resettable Ah
Clear Total Ah
STATUS
HISTORY
Error Log
See Complete History
Screens Online, or in
Manual Insert
Graphs
SYSTEM
CUSTOM PROGRAMMING:
See Complete
Programming Screens
Online or in Manual Insert
To
Programming
Screens
Serial No.
Firmware Version
Battery Type
Absorption Voltage
Float Voltage
EQ Voltage
Input Mode
System Voltage
Faults
Alarms
Charge State
Load / Light State
Target Voltage
Battery Temp.
Battery Sense
Input Voltage
Last Equalization
Hour Meter
Clear KWh
Load Disconnect
Start Lighting Test
Factory Reset
Reset Control
Records
DISPLAY
SETTINGS
See Complete
Programming Screens
Online or in Manual Insert
Backlight
Backlight Timer
Contrast
Brightness
Auto Scroll
Auto Scroll Timer
Auto Return
Temp. Units
Language
Figure 4-7. Simplified Meter Map. For metered models, see
the included complete meter map insert, also available in the
ProStar MPPT support documents at:
www.morningstarcorp.com
ProStar MPPT Operator’s Manual
53
4.7.2 Programming in MSView
Beyond the preset DIP switch options, the Prostar MPPT's
charging profile and all other settings are customizable
using MSView PC software available at:
www.morningstarcorp.com
WARNING: Risk Of Electrical Shock.
Hazardous voltage is present at the Meterbus
communications port. Use 150V rated, 4 or 6 conductor UL
listed telephone cable.
AVERTISSEMENT: Risque de choc électrique.
Tension dangereuse est présente dans le port de
communication de transfert. Utilisez 150V évalué, 4 ou 6
conducteurs câble de téléphone répertorié UL.
With a connection to a PC, and using the ProStar MPPT
Set-up Wizard, the software is capable of editing all charging and lighting parameters for upload to the controller.
The Set-up Wizard, and topics within the Help tab describe
programming procedures in detail.
All aspects of connection, programming and
communications are covered in the Product Connectivity
Manual:
www.morningstarcorp.com\resources\white papers and
documents
Communications accessories / adapters should be housed in
the optional Wire Box for ProStar MPPT.
54
Operation
4.7.3
Meter Display Operation
4.7.3.1 Directional Key Use and Operation / Navigating
the Meter Map
The ProStar MPPT's meter map consists of two main axes:
The horizontal top level daily monitoring screens, and
the vertical Main Menu stacked screens. The four lighted
triangular directional control keys allow movement to reach
any desired point on the meter map. A lit key indicates
a valid direction in the map. The current location is indicated on the display with a column heading, and a bold
descriptor.
4.7.3.2 Adjusting the Meter Display
4.7.4 Using the Meter Display to Program Charging
Set-points, Load Control, Communications, and Advanced
Settings
Refer to the complete meter map insert for metered PSMPPTs. From a top level monitoring screens, scroll down to
the Main Menu - "Custom Programming" - screen. Select
the desired category, and edit the variable or settings as
as instructed in the meter display.
The Load Control category includes Normal (load disconnect) and Lighting programming. The Advanced Settings
category includes more optional charging, MPPT, and load
control settings.
NOTE: Without DIPs 4,5,6 ON (up), only COM address
settings options will appear in the meter map. To view and
program custom settings via the meter display, DIPs 4,5,6
must be in the ON (up) position.
4.7.5 Lighting Control / Programming Overview
The ProStar MPPT display has extensive lighting load
programmability.
ProStar MPPT Operator’s Manual
55
4.0
The display setting options, as shown in Figure 4-7, are
adjustable by using the directional keys to locate and edit a
desired setting or variable.
With DIP switch 1 ON (up), a dusk-dawn lighting program
is enabled, if lighting timing hasn't been programmed in
MSView or using the meter; with DIP 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 for setting timers that can work separately, or
in combination. See Section 4.6.6 - Lighting Programming
Using Meter Display - for more details.
4.7.6 Lighting Programming Using the Meter Display
Lighting programming capabilities are accessible with the
meter via Custom Programming->Load Control->Lighting.
Lighting settings editing is done via on-screen instructions.
• The Summary provides a graphical representation of the
complete lighting configuration
• LVD / LVR can be specified for use when a lighting
program is in operation
• Sunrise and Sunset Threshold settings allow the adjustment of percentages of the maximum seen solar array
voltage for triggering day and night events
• There are four channels, each having two timers, which
can be used independently, or in combination.
• Events and actions are used as references and controls.
An event is one of eight points in a day e.g. sunrise or
midnight. Each event can be edited to specify a time
offset to trigger an action, which can be, "Do Nothing",
"Lights On", or "Lights Off"
• The combination setting of each channel will specify
whether the actions and events of each timer will function:
not at all (no combination); when both timers' settings
match (AND); for either timers' settings (OR)
56
Operation
4.8 Inspection and Maintenance
Table 4-6 below lists the recommended maintenance
schedule to keep your ProStar MPPT performing optimally.
WARNING: RISK OF ELECTRICAL SHOCK.
NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROM DC INPUT, AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN
FAULT CONDITIONS, BATTERY COULD BECOME OVERCHARGED. TEST BETWEEN ALL TERMINALS AND GROUND
BEFORE TOUCHING.
WARNING: Shock Hazard
Disconnect all power sources to the controller before
removing the wiring box cover. Never remove the cover when
voltage exists on the ProStar MPPT power connections.
AVERTISSEMENT: Risque de décharge électrique
Un moyen de déconnexion de tous les poteaux
d'alimentation doit être fourni. Ceux-ci se déconnecte doit
être intégrée dans le câblage fixe. Ouvrir que toutes les source
d'énergie se déconnecte avant de retirer le couvercle de la
contrôleur, ou accès au câblage.
ProStar MPPT Operator’s Manual
57
4.0
AVERTISSEMENT: RISQUE DE CHOC ÉLETRIQUE.
NON ALIMENTATION OU AUX BORNES
D'ACCESSOIRES SONT ISOLÉS ÉLECTRIQUEMENT DE
L'ENTRÉE DE C.C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION
DANGEREUSE SOLAIRE. SOUS CERTAINES CONDITIONS DE
DÉFAILLANCE, LA BATTERIE POURRAIT DEVENIR TROP CHARGÉE. 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
torque values.
3 months after installation
Re-tighten power terminal
connections to specified
torque values.
Monthly or After Each
Equalization
Inspect the battery bank.
Look for cracked or
bulging cases, and corroded
terminals.
For wet cell (flooded type)
batteries, make sure the
water level is correct. Wet
cell water levels should be
checked monthly or according to the manufacturer’s
recommendations.
Clean the heatsink fins with a
clean, dry rag.
Inspect all wiring for
damage or fraying.
Inspect for nesting insects.
Annually
Re-tighten all wiring terminal
connections to specified
torque values.
Inspect the system earth
grounding for all components. Verify all grounding
conductors are appropriately
secured to earth ground.
58
Table 4-6. Maintenance Schedule
Operation
5.0TROUBLESHOOTING
WARNING: RISK OF ELECTRICAL SHOCK.
NO POWER OR ACCESSORY TERMINALS ARE ELECTRICALLY ISOLATED FROM DC INPUT, AND MAY BE ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN
FAULT CONDITIONS, BATTERY COULD BECOME OVERCHARGED. TEST BETWEEN ALL TERMINALS AND GROUND
BEFORE TOUCHING.
AVERTISSEMENT: RISQUE DE CHOC ÉLECTRIQUE.
NON ALIMENTATION OU AUX BORNES
D'ACCESSOIRES SONT ISOLÉS ÉLECTRIQUEMENT DE
L'ENTRÉE DE C.C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION
DANGEREUSE SOLAIRE. SOUS CERTAINES CONDITIONS DE
DÉFAILLANCE, LA BATTERIE POURRAIT DEVENIR TROP CHARGÉE. TEST ENTRE TOUTES LES BORNES ET LA MASSE AVANT
DE TOUCHER.
AVERTISSEMENT: Risque de décharge électrique
Un moyen de déconnexion de tous les poteaux
d'alimentation doit être fourni. Ceux-ci se déconnecte doit
être intégrée dans le câblage fixe. Ouvrir que toutes les source
d'énergie se déconnecte avant de retirer le couvercle de la
contrôleur, ou accès au câblage.
5.1 LED Fault Indications
Load Over-current
Error Status LED: Flashing red. Battery status LEDs: R/YG sequencing. If the load current exceeds the maximum
load current rating, the ProStar MPPT will disconnect the
load. The greater the overload the faster the load will be
ProStar MPPT Operator’s Manual
59
5.0
WARNING: Shock Hazard
A means of disconnecting all power supply poles must
be provided. These disconnects must be incorporated
in the fixed wiring. Open all power source disconnects before
removing controller wiring cover, or accessing wiring.
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 overload remains after two (2)
attempts, the load will remain disconnected until power is
removed and re-applied.
Solar Short Circuit
Charging Status LED: OFF. Solar input power wires are
short-circuited. Charging automatically resumes when the
short is cleared.
Battery Reverse Polarity
No LED indication, the unit is not powered. No damage to
the controller will result. Correct the miswire to resume
normal operation.
Load Short Circuit
Error status LED: Flashing red. Battery status LEDs: R/G-Y
sequencing. Fully protected against load wiring shortcircuits. After two (2) automatic load reconnect attempts (10
seconds between each attempt), the fault must be cleared
by removing and re-applying power.
High Solar Voltage Disconnect
Charging Status LED: R flashing. No battery status errors.
If the solar input open-circuit voltage (Voc) exceeds the 120
volt maximum rating, the array will remain disconnected
until the Voc falls safely below the maximum rating.
Remote Temperature Sensor (RTS)
Error status LED: Flashing red. Battery status LEDs: R/Y G/Y sequencing. A bad RTS connection or a severed RTS
wire has disconnected the temperature sensor during
charging. Charging automatically resumes when the
problem is fixed. To resume operation without an RTS,
disconnect all power to the ProStar MPPT and then
reconnect. If the controller is re-started with the failure still
present, the controller may not detect that the RTS is connected, and the LEDs will not indicate a fault. A metered
model, an RM-1 meter, or MSView PC software
60
Troubleshooting
can be used to determine if the RTS is working properly.
Battery Sense Cables Issue
Error status LED: Flashing red. Battery status LEDs:
R/Y - G/Y sequencing. If a fault in the battery sense
connection (such as a short-circuit, open circuit or loose
terminal) occurs after the battery sense has been working,
the LEDs will indicate a failure. To resume operation without
battery sense cables, disconnect all power to the ProStar
MPPT and then re-connect. If the controller is re-started
with the failure still present, the controller may not detect
that the battery sense is connected, and the LEDs will not
indicate a fault. An RM-1 meter, or MSView PC software,
can be used to determine if the battery sense is working
properly.
High Heatsink Temperature
Error status LED: Flashing red. Battery status LEDs: R-Y
sequencing. The heatsink temperature has exceeded safe
limits and the load is disconnected. The load will automatically reconnect when the heatsink cools to a safe
temperature.
ProStar MPPT Operator’s Manual
61
5.0
Battery / Load High Voltage Disconnect (HVD)
Error status LED: Flashing red. Battery status LEDs: R-G
sequencing. This fault is set when battery voltage is above
normal operating limits. The controller will disconnect the
solar input and set a High Voltage Disconnect fault. This
fault is commonly caused by other charging sources in the
system, charging the battery above the ProStar MPPT regulation voltage. Recovery occurs at HVD re-connect threshold, and the fault will automatically clear. See Section 7 Technical Specifications for values.
Battery Over-Current
Error status LED: Flashing red. Battery status LEDs:
R/Y-G sequencing. While rare, if battery charging current
exceeds approximately 130% of the controller’s output
current rating, this fault can occur. The fault is generally
related to fast, large battery voltage transients (connecting a
very heavy or capacitive load like an inverter) that are faster
than the controller can regulate and it shuts off to protect
the circuitry. The controller will automatically re-start in 10
seconds.
Settings (DIP) Switch Changed
Error status LED: Flashing red. Battery status LEDs: R-Y-G
sequencing. If a settings switch is changed while there is
power to the controller, the LEDs will begin sequencing and
the solar input will disconnect. The controller must be restarted to clear the fault and begin operation with the new
settings.
Custom Settings Edit
Error status LED: Flashing red. Battery status LEDs: R-Y-G
sequencing.
A value has been modified in custom settings memory.
The controller will stop charging and indicate a fault condition. After all settings have been modified, the controller
must be reset by removing and then restoring power to the
controller. The new programmed settings will be used after
the power reset.
Firmware Update Failure
The firmware update was not successfully programmed. The
controller will not indicate the full power-up LED sequence
of G-Y-R when power to the controller is reset. Instead, the
controller will display green, and then stop on yellow. The
yellow LED will continue to be lit and the controller will not
complete start up or begin charging. Retry the firmware
update. The firmware must be successfully loaded before
the controller will start up.
62
Troubleshooting
SOLID CHARGING STATUS LED with SELF-TEST (R-Y-G)
SOC FAULTS
Verify that nothing has been mis-wired. If not, the error is
likely critical. Contact an authorized Morningstar dealer for
support.
Fault
Charging Status LED
Battery SOC LEDs
PV FET Short
Solid red
R-Y-G sequencing
Load FET Short
Solid red
R-Y-G sequencing
Load FET Open
Solid red
R-Y-G sequencing
Damaged local
temperature sensor
Solid red (only if RTS
is invalid)
R-Y-G sequencing
Damaged heatsink
temperature sensor
Solid red
R-Y-G sequencing
Software
Solid red
R-Y-G sequencing
5.0
RE-SETTABLE SELF-TEST (R-Y-G) SOC FAULTS
Fault
Custom Settings Edit
DIP Switch Change
-
Battery SOC LEDs
R-Y-G sequencing
R-Y-G sequencing
ProStar MPPT Operator’s Manual
63
5.2 Battery Charging and Performance Issues
Problem:
No LED indications, controller does not appear to be
powered
Solution:
With a multi-meter, check the voltage at the battery
terminals on the ProStar 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 for service.
If no voltage is measured, check wiring connections, fuses,
and breakers.
Problem:
The ProStar MPPT is not charging the battery.
Solution:
Check the three (3) battery SOC LEDs. If they are flashing in
a sequence, see Section 4.5 LED indications of this manual
to determine the cause. A metered model, an RM-1 meter,
or MSView PC software will display active faults and alarms.
If the LED indications are normal, check the fuses,
breakers, and wiring connections in the power source wiring. With a multi-meter, check the array voltage directly at
the ProStar MPPT solar input terminals. Input voltage must
be greater than battery voltage before charging will begin.
Problem:
Controller makes buzzing and humming noises.
Solution:
No action is required. This is expected due to magnetic
resonance and circuit switching.
If troubleshooting does not correct the problem, please
refer to Morningstar's Warranty Claim Procedure in
Section 6.
64
Troubleshooting
6.0
WARRANTY & POLICIES
LIMITED WARRANTY Morningstar Solar Controllers and Inverters
All of Morningstar’s products, with the exception of the SureSine™ 300 inverter and SHS™ controller, are warrantied to be
free from defects in material and workmanship for a period of
FIVE (5) years from the date of shipment to the original end user.
Morningstar’s SureSine 300 Inverter and SHS products are warrantied to be free from defects in material and workmanship for a
period of TWO (2) years from the date of shipment to the original
end user. Morningstar will, at its option, repair or replace any
such defective products.
WARRANTY EXCLUSIONS AND LIMITATIONS:
This warranty does not apply under the following conditions:
♦ Damage by accident, negligence, abuse or improper use
♦ PV or load currents exceeding the ratings of the product
♦ Unauthorized product modification or attempted repair
♦ Damage occurring during shipment
THE WARRANTY AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE AND IN LIEU OF ALL OTHERS, EXPRESS OR IMPLIED.
MORNINGSTAR SPECIFICALLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. NO MORNINGSTAR DISTRIBUTOR, AGENT OR
EMPLOYEE IS AUTHORIZED TO MAKE ANY MODIFICATION OR
EXTENSION TO THIS WARRANTY.
6.0
♦ Damage results from acts of nature such as lightning and
weather extremes
MORNINGSTAR IS NOT RESPONSIBLE FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES OF ANY KIND, INCLUDING BUT
NOT LIMITED TO LOST PROFITS, DOWN-TIME, GOODWILL OR
DAMAGE TO EQUIPMENT OR PROPERTY.
ProStar MPPT Operator’s Manual
R15-8/15
65
MORNINGSTAR TECHNICAL SUPPORT POLICIES
Morningstar’s Technical Support Group is dedicated to
providing unparalleled customer support.
MS Support Scope:
1. Determining correct or failed functionality of a
Morningstar product or system of Morningstar devices. It
is expected that owners/operators will use manuals (including trouble shooting sections) before requesting technical
support.
2. Providing product warranty replacements in accordance
with the terms of Morningstar’s warranty policy.
3. Assisting with the operability of all product / system
features and functions described in Morningstar manuals
and datasheets.
Please be advised:
♦ The Morningstar Technical Support Group generally
provides referrals for requested system consultations or
design/configuration/sizing services. Distributors, dealers, system designers, installers and vast online resources
- including the String Calculator array design tool (at www.
morningstarcorp.com) - are available to assist in these areas.
Morningstar can help refer customers to a nearby authorized distributor, dealer, or installer if assistance is required
in designing a renewable energy system that best suits your
specific needs.
66
Warranty and Policies
MORNINGSTAR TECHNICAL SUPPORT POLICIES (Cont.)
♦ Please visit the Tech Support section at
www.morningstarcorp.com for any documentation or
specification needs before requesting support. The site
also offers an array sizing tool (String Selector), product
comparison tool (Product Comparator) and articles on solar
charging technologies and other design considerations.
♦ Although emergencies do arise when a phone call is
necessary, e-mail is the best way to contact us, and will
result in the quickest response. Please use the support
request form Contact Us (preferred), or e-mail us directly at
support@morningstarcorp.com
Thank you for your business, and we look forward to
assisting you.
6.0
ProStar MPPT Operator’s Manual
67
WARRANTY CLAIM PROCEDURE
1. Before proceeding, please refer to product manual,
including Trouble Shooting section.
2. Contacting your authorized Morningstar distributor or
dealer from whom you purchased the unit is
the first step in the warranty process. Local dealers can often
address warranty issues quickly.
3. If supplier is unable to address the issue, please contact
Morningstar by e-mail (support@morningstarcorp.com) with:
(A) purchase location -- business or company name
(B) full model and serial numbers (SN is 8-digits on unit
bar label)
(C) failure behavior, including LED indications
(D) array configuration, panel Pmax, Voc, Vmp, Isc, and
nominal battery voltage; these specifications are
needed to receive assistance.
(E) multi-meter available (for field troubleshooting)
4. After warranty replacement has been approved and new
unit(s) received, please return failed unit(s) using pre-paid
shipping label, and follow any product specific instructions if
requested by Morningstar Warranty Dept.
5. If instructed by Morningstar, after warranty replacement
shipment has been received, return of failed unit(s) is
required before further warranty replacements can be
considered for the original or future cases.
NOTE: Please do not return units without an RMA or
case number. Doing so will increase the time required to
resolve your claim.
68
Warranty and Policies
7.0
TECHNICAL SPECIFICATIONS
PS-MPPT-15 PS-MPPT-25
PS-MPPT-40
PS-MPPT-15M PS-MPPT-25M PS-MPPT-40M
Electrical:
Nominal Battery Voltage
12 volts or 24 volts (all)
Battery Voltage Range
10-35 volts (all)
Voltage Accuracy
0.1% +/- 50mV (all)
Max. Battery Current
15 amps
25 amps
40 amps
Max. PV Open-Circuit Voltage
120 volts (all)
Load Current Rating
25 amps
25 amps
30 amps
Self Consumption
< 25mA (no meter) <40mA (meter)
LED Indications
(1) status, (3) battery SOC
Transient Surge Protection
4500 watts (solar, battery, load)
Conversion Efficiency (peak)
97.3% (all)
Mechanical:
Dimensions:
Standard
7.87(W) x 6.69(L) x 2.76(D) in. /
20.0(W) x 17.0(L) x 7.0(D) cm
Wire Box Option
7.87(W) x 11.22(L) x 3.62(D) in. /
20.0 (W) x 28.5 (L) x 9.2(D) cm
Weight:
Standard Version
3.1 lb /1.4 kg
Standard Version with Wire Box
3.4 lb /1.5 kg
Wire Size Range:
Power Terminals
2.5 - 16 mm2 / #14 - 6* AWG
(maximum torque)
35 in-lb
Battery/Temp. Sense
0.25 - 1.0 mm2 / #24 - 16 AWG
Knock-outs (wire box option only)
M20, 1/2", 1" (trade sizes)
Enclosure IP20, Type 1
Battery Charging:
4-Stage Charging:
Temperature compensation
Coefficient:
Temperature compensated
set-points:
Bulk, Absorption, Float, Equalize
-30mV / 12 volt / ºC
Absorption, Float, Equalize, HVD
* With Wire Box, up to #2 AWG
Technical Specifications
69
Battery Charging Set-points (@ 25°C):
[multiply voltages by (2) for 24 volt systems]
DIP
Switch
Settings
4-5-6
Absorp.
Stage
(volts)
Float
Stage
(volts)
off-off-off 1 - Sealed*
14.00
13.70
off-off-on 2 - Sealed*
14.15
13.70
14.40
off-on-off 3 - Sealed*
14.30
13.70
14.65
off-on-on
14.40
13.70
on-off-off 5 - Flooded
14.60
on-off-on
6 - Flooded
14.70
on-on-off
7 - L-16
on-on-on
8 - Custom
Battery
Type
4- AGM/Flooded
Equalize
Stage
(volts)
Absorp.
Time
(mins)
Equalize
Time
(mins)
Equalize
Timeout
(mins)
Equalize
Interval
(days)
150
60
120
28
150
60
120
28
15.10
180
120
180
28
13.50
15.30
180
120
180
28
13.50
15.40
180
180
240
28
15.40
13.40
16.00
180
180
240
14
Custom
Custom
Custom
Custom
Custom
Custom
Custom
150
“Sealed” battery
type
includes
gel andgel
AGM
batteries
* *“Sealed”
battery
type
includes
and
AGM batteries
Current Compensation:
12 volt systems
24 volt systems
Compensated set-points
Compensation threshold
-20 mV / A
-40 mV / A
LVD
3A
Load and Solar Control (multiply voltages by (2) for 24 volt
systems):
Default values(customizable)
LVD
11.4V
LVDR 12.6V
Instant LVD
10.0V
HVD - load
15.3V (@ 25ºC)
HVD - solar
15.2V (@ 25ºC)
HVDR - load
14.5V (@ 25ºC)
HVDR - solar
12.3V (@ 25ºC)
LVD Warning
10 minutes
LVD Override
10 minutes
Maximum # LVD overrides
No limit unless
(not customizable)
V_batt < Instant LVD
Lighting Control (DIP 1 ON):
Lighting Timer Setting
Lighting Test Timer
70
Dusk-Dawn (default)
5 minutes
Technical Specifications
Data & Communications:
Communication Port
Comm. Protocols
Datalogging
PC Software
MeterBus
Morningstar MeterBus; MODBUS
6-8 months, daily records
MSView
Digital Meter:
Resolution
128 x 64
Viewing Area
70mm x 40mm
Display Color
blue on white
Backlight LED
Operating Temperature
-20C to +70C
Storage Temperature
-30C to +80C
Environmental:
Operating Altitude
Operating Temperature
Storage Temperature
Humidity
Tropicalization
Below 2000 meters
-40C to +45C
-40C to +80C
100% n.c.
Conformally coated PCBs;
Marine-rated terminals
Protections
ProStar MPPT Operator’s Manual
7.0
Power-up against any active faults
Reverse Polarity - battery and array
Solar Short-Circuit
Solar High Voltage Disconnect
High Heatsink Temperature - Current De-rating
High Heatsink Temperature - Load Disconnect
Load Short-Circuit
Load Over-Current
Heatsink Temperature Limit
RTS Terminals
Battery Sense Terminals
71
100.00%
99.00%
98.00%
97.00%
96.00%
95.00%
94.00%
93.00%
92.00%
91.00%
90.00%
89.00%
88.00%
87.00%
86.00%
85.00%
84.00%
83.00%
82.00%
81.00%
80.00%
79.00%
78.00%
77.00%
76.00%
75.00%
74.00%
73.00%
72.00%
71.00%
70.00%
0
50
100
72
150
200
Appendices
300
350
Output Power (Watts)
250
400
ProStar MPPT Efficiency 12 Volt System
450
500
550
93 Vmp
62 Vmp
31 Vmp
600
APPENDIX A - Efficiency Graphs
Efficiency (%)
Efficiency (%)
100.00%
99.00%
98.00%
97.00%
96.00%
95.00%
94.00%
93.00%
92.00%
91.00%
90.00%
89.00%
88.00%
87.00%
86.00%
85.00%
84.00%
83.00%
82.00%
81.00%
80.00%
79.00%
78.00%
77.00%
76.00%
75.00%
74.00%
73.00%
72.00%
71.00%
70.00%
Appendices
ProStar MPPT Operator’s Manual
73
0
50
100
150
200
250
300
350
400
450
550
600
650
700
Output Power (Watts)
500
750
800
ProStar MPPT Efficiency 24 Volt System
850
900
950 1000 1050 1100 1150
93 Vmp
62 Vmp
APPENDIX B - De-rating Graphs
O V E R - V O L T A G E
40
R A N G E !
Battery Current (Amps)
Battery Current vs. Array Voltage (Vmp)
0
80
85
90
95
100
105
110
115
120
Array Voltage (Volts)
Battery Current vs. Ambient Temperature
100Vmp
80Vmp
60Vmp
40Vmp
20Vmp
Battery Current (Amps)
45
40
35
30
25
20
15
10
5
0
10
20
25 30 32 33 34 35 36 37 38 39 40 41 42 43
44
45 46 47 48 49
50 51 52 53 54 55 56 57
Ambient Temperature (degrees C)
74
Appendices
58
59
60 61
62
APPENDIX C - Wire Sizing Charts
2% Voltage Drop Charts for 75°C Stranded Copper Wire
1-Way Wire Distance (feet), 12 Volt System
Wire Size
(AWG)
40A
35A
30A
25A
20A
15A
10A
5A
2/0 *
33.6
38.4
44.8
53.8
67.2
89.6
134.4
268.9
1/0 *
26.6
30.4
35.5
42.6
53.3
71.0
106.6
213.1
2
16.8
19.1
22.3
26.8
33.5
44.7
67.0
134.0
4
10.6
12.1
14.1
16.9
21.1
28.1
42.2
84.4
6
6.6
7.6
8.8
10.6
13.2
17.7
26.5
53.0
8
4.2
4.8
5.6
6.7
8.4
11.1
16.7
33.4
10
2.6
3.0
3.5
4.2
5.2
7.0
6.6
21.0
12
1.6
1.9
2.2
2.6
3.3
4.4
6.6
13.1
14
1.0
1.2
1.4
1.7
2.1
2.8
4.1
8.3
Table C-1. Maximum 1-way wire distance for 12 Volt 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
16.24
21.65
32.48
64.96
35
5.11
5.84
6.81
8.17
10.21
13.62
20.42
40.85
25
3.22
3.68
4.29
5.15
6.43
8.58
12.87
25.73
16
2.02
2.31
2.69
3.23
4.04
5.38
8.07
16.14
10
1.27
1.46
1.70
2.04
2.55
3.40
5.09
10.19
6
0.80
0.91
1.07
1.28
1.60
2.13
3.20
6.39
4
0.50
0.57
0.67
0.80
1.00
1.33
2.00
4.00
2.5
0.32
0.36
0.42
0.50
0.63
0.84
1.26
2.52
ProStar MPPT Operator’s Manual
Appendices
Table C-2. Maximum 1-way wire distance for 12 Volt systems, solid
copper, 2% voltage drop
75
2% Voltage Drop Charts for 75°C Solid Copper Wire
1-Way Wire Distance (feet), 12 Volt System
Wire Size
(AWG)
40A
35A
30A
25A
20A
15A
10A
5A
2/0 *
41.7
47.7
55.6
66.7
83.4
111.2 166.8
333.6
1/0 *
33.1
37.8
44.1
52.9
66.1
88.2
132.3
264.6
2
20.8
23.8
27.7
33.3
41.6
55.4
83.2
166.3
4
13.1
14.9
17.4
20.9
26.2
34.9
52.3
104.6
6
8.2
9.4
11.0
13.2
16.5
21.9
32.9
65.8
8
5.2
5.9
6.9
8.3
10.3
13.8
20.7
41.4
10
3.3
3.7
4.3
5.2
6.5
8.7
13.0
26.0
12
2.0
2.3
2.7
3.3
4.1
5.5
8.2
16.4
14
1.3
1.5
1.7
2.1
2.6
3.4
5.1
10.3
Table C-3. Maximum 1-way wire distance for 12 Volt 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 *
12.71
14.53
16.95
20.34
25.42
33.90
50.85 101.69
50 *
10.08
11.52
13.44
16.13
20.16
26.88
40.32
80.64
35
6.34
7.24
8.45
10.14
12.68
16.90
25.35
50.70
25
3.99
4.56
5.32
6.38
7.97
10.63
15.95
31.89
16
2.51
2.87
3.34
4.01
5.01
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-4. Maximum 1-way wire distance for 12 Volt systems, solid
copper, 2% voltage drop
76
Appendices
*Wires sizes larger than 2 AWG (35 mm2) must be terminated at a splicer
block located outside of the ProStar MPPT wiring box. Use 2 AWG
(35 mm2) or smaller wire to connect to the ProStar MPPT to the splicer
block.
Notes:
• The specified wire length is for a pair of conductors
from the solar or battery source to the controller (1-way
distance)
• For 24 volt systems, multiply the 1-way length in the table
by 2.
• Shaded cells in the table indicate that the current exceeds
the ampacity of the wire for a given ambient temperature
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 temperature
Exceeds wire ampacity at 30°C ambient temperature
**Ampacity for not more than three
current-carrying conductors in a raceway,
cable, or earth (buried) - Per 2011 NEC
Appendices
ProStar MPPT Operator’s Manual
77
2% Voltage Drop Charts for 90°C Stranded Copper Wire
1-Way Wire Distance (feet), 12 Volt System
Wire Size
(AWG)
40A
35A
30A
25A
20A
15A
10A
5A
2/0 *
33.6
38.4
44.8
53.8
67.2
89.6
134.4
268.9
1/0 *
26.6
30.4
35.5
42.6
53.3
71.0
106.6
213.1
2
16.8
19.1
22.3
26.8
33.5
44.7
67.0
134.0
4
10.6
12.1
14.1
16.9
21.1
28.1
42.2
84.4
6
6.6
7.6
8.8
10.6
13.2
17.7
26.5
53.0
8
4.2
4.8
5.6
6.7
8.4
11.1
16.7
33.4
10
2.6
3.0
3.5
4.2
5.2
7.0
10.5
21.0
12
1.6
1.9
2.2
2.6
3.3
4.4
6.6
13.1
14
1.0
1.2
1.4
1.7
2.1
2.8
4.1
8.3
Table C-5. Maximum 1-way wire distance for 12 Volt systems, stranded
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
16.24
21.65 32.48 64.96
35
5.11
5.84
6.81
8.17
10.21
13.62 20.42 40.85
25
3.22
3.68
4.29
5.15
6.43
8.58
12.87 25.73
16
2.02
2.31
2.69
3.23
4.04
5.38
8.07
16.14
10
1.27
1.46
1.70
2.04
2.55
3.40
5.09
10.19
6
0.80
0.91
1.07
1.28
1.60
2.13
3.20
6.39
4
0.50
0.57
0.67
0.80
1.00
1.33
2.00
4.00
2.5
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
78
Appendices
2% Voltage Drop Charts for 90°C Solid Copper Wire
1-Way Wire Distance (feet), 12 Volt System
Wire Size
(AWG)
40A
35A
30A
25A
20A
15A
10A
5A
2/0 *
41.7
47.7
55.6
66.7
83.4
111.2
166.8
333.6
1/0 *
33.1
37.8
44.1
52.9
66.1
88.2
132.3
264.6
2
20.8
23.8
27.7
33.3
41.6
55.4
83.2
166.3
4
13.1
14.9
17.4
20.9
26.2
34.9
52.3
104.6
6
8.2
9.4
11.0
13.2
16.5
21.9
32.9
65.8
8
5.2
5.9
6.9
8.3
10.3
13.8
20.7
41.4
10
3.3
3.7
4.3
5.2
6.5
8.7
13.0
26.0
12
2.0
2.3
2.7
3.3
4.1
5.5
8.2
16.4
14
1.3
1.5
1.7
2.1
2.6
3.4
5.1
10.3
Table C-7. Maximum 1-way wire distance for 12 Volt 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 *
12.71
14.53
16.95
20.34
25.42
33.90
50.85 101.69
50 *
10.08
11.52
13.44
16.13
20.16
26.88
40.32
80.64
35
6.34
7.24
8.45
10.14
12.68
16.90
25.35
50.70
25
3.99
4.56
5.32
6.38
7.97
10.63
15.95
31.89
16
2.51
2.87
3.34
4.01
5.01
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-8. Maximum 1-way wire distance for 12 Volt systems, solid
copper, 2% voltage drop
Appendices
ProStar MPPT Operator’s Manual
79
*Wires sizes larger than 2 AWG (35 mm2) must be terminated at a splicer
block located outside of the ProStar MPPT wiring box. Use 2 AWG
(35 mm2) or smaller wire to connect to the ProStar MPPT to the splicer
block.
Notes:
• The specified wire length is for a pair of conductors from
the solar or battery source to the
controller (1-way distance)
• For 24 volt systems, multiply the 1-way length in the table
by 2.
• Shaded cells in the table indicate that the current exceeds
the ampacity of the wire for a given ambient temperature
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 temperature
Exceeds wire ampacity at 30°C ambient temperature
**Ampacity for not more than three
current-carrying conductors in a raceway,
cable, or earth (buried) - Per 2011 NEC
80
Appendices
8.0CERTIFICATIONS
ALL
COMPONENTS
REACH
COMPLIANT
Registration, Evaluation and
Authorization of Chemicals
• Complies with UL 1741, UL 62109 and
CSA-C22.2 No. 107.1
• IEC 62109
• Complies with the US National Electric Code
• Complies with the Canadian Electrical Code
• FCC Class B compliant
ENs Directives:
• Complies with ENs and LVD standards for CE marking
• Immunity: EN 61000-4-3: 2006
EN 61000- 4-6: 2009
• Emissions: CISPR 22: 2008
ProStar MPPTTM, MeterBusTM are trademarks of Morningstar
Corporation
MODBUSTM and MODBUS TCP/IPTM are trademarks of
Modbus IDA. www.modbus-ida.org
© 2015 Morningstar Corporation. All rights reserved.
MS-001537 v1.2
Certifications
81
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