Solar PV Electric

ProStar Controller

PV System Component

ProStar™ Solar Controller

Morningstar Corporation introduces the new ProStar solar charge controller. The ProStar was first marketed to the solar industry in 1995 and has since become the world's leading mid-range controller for both professional and consumer applications.

By using highly advanced technology, this second generation ProStar sets new standards for reliability and self-diagnostics. The new ProStar also provides several unique features and protections. And Morningstar's patented PWM battery charging has been further optimized for longer battery life and improved system performance.

The new ProStar is available in 15 or 30 amps, 12/24 or 48 volt, and negative or positive ground. The controller may be paralleled for a solar input rating of up to 300 amps. An optional meter provides an extensive display of self-testing and system status.

ProStar Versions
The standard ProStar versions have been reduced by two-thirds to cut inventory and logistic costs.

. Original 12 versions reduced to 4
. New positive ground and 48 volt versions have been added

Reliability
Expected failure rate will be less than 1 per 1,000 units over 5 years.

. Improved protections and added many new protections
. (see list below)
. Power MOSFET voltage rating increased 25%
. Eliminated all trim-pots and other troublesome parts
. Reduced the digital meter components from 75 to 16
. Increased the current-carrying copper traces by 75%
. Increased temperature rating of many parts
. Made conformal coating protection standard

Battery Charging
Expanded the battery charging options and capabilities.

. Added a third battery type selection (gel, sealed, flooded)
. Added a "float" stage to the battery charging algorithm
. Expanded the to account for depth of discharge history
. Added a remote temperature probe option
. Improved the accuracy of all charging parameters
. Moved the built-in temperature sensor to read ambient
. conditions more accurately

Installation & Operation
The new ProStar is easier and safer to install and use, with more operating information provided to the user.

. Self-diagnostic test provides assurance the controller is working
. correctly, or indicates a fault that is present
. Rotary switch provides simple and positive selection of battery
. type (and LED's confirm the selection)
. Terminals are longer with more screw threads, screwdriver holes
. in the case are larger, and plastic tabs isolate the terminals
. The pushbutton disconnects the load first (for weekend cabins,
. boats, etc.), then disconnects the solar if held down for 2 seconds
. (indicated in the meter)
. Five protection functions are displayed in the digital meter
. Meter indicates "OFF" if solar or load is disconnected
. PWM is indicated in the green battery status LED (blinking)
. A telecom jumper eliminates PWM noise if present
. Mounting standoffs prevent stress cracks in the case

Protections
Protection against abuse and faults is now comprehensive.

. Added solar short circuit and overload protection / auto recovery
. Added load overload protection / auto recovery
. Improved load short circuit protection / auto recovery
. Improved protection of the load from voltage spikes
. Improved low battery voltage and brownout protection / auto
. recovery
. Other existing protections have been improved

Accuracy
Precision design for improved performance and accurate meter display.

. Added 0.1% resistors and other precision components
. Upgraded to a more powerful, faster microcontroller with better
. resolution
. Extensive digital filtering for improved accuracy
. Added 2 precision shunts for very accurate current measurement
. Calibration of the microcontroller during final QA testing in
. production

Digital Meter Display
Completely redesigned, improved and expanded the digital meter.

. Meter reads values directly from the microcontroller
. Very accurate voltage and current values measured and displayed
. Added self-test with specific faults and conditions displayed
. More status and protection conditions are displayed
. Reduced self-consumption to 1 mA
. Current is now measured in the ungrounded leg only
. Meter connector is more robust and easier to attach
. Any meter can now be mounted to any ProStar with no calibration
. required

Product Benefits:
Highest Reliability - It is almost impossible to "kill" the ProStar due to large design margins and electronic protections.
. No need to derate...use up to full "nameplate" ratings
. Rated for operating temperatures from -30°C to +60°C
. Short-circuit, overload and reverse polarity protected...with
. automatic electronic recovery

More Information - The LED’s indicate various battery and system status. The meter option now displays extensive data:
. Accurate readings of PV current, load current, and system voltage
. Temperature
. LVD and other disconnect conditions
. Self-test mode which displays 9 different controller status
. parameters and any detected faults (makes it very easy to
. troubleshoot)

Longer Battery Life - The ProStar’s constant voltage PWM regulation now uses 4 stages of charging including float charging. Battery type selections are made via rotary switch and include gel, sealed or flooded.

Tropicalizaton - All ProStars now include conformal coating, stainless-steel screws and an anodized aluminum heat sink (protection for marine and jungle environments).

48V and Positive Ground - New versions of the ProStar also include 15A at 48V (negative and positive ground) and a 30A at 12/24V for positive grounded systems.

Low Telecom Noise - The new ProStar has been designed for reduced interference during PWM regulation. The regulation frequency may be further reduced in the field.

Remote Temperature Probe - The ProStar now has an optional remote temperature probe for sites where the controller and battery experience different temperatures.

Product Specifications:

Product Manufacturer: MorningStar

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