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Title Type Language Date Version Rating
Remote Temperature Sensor Datasheet application/pdf English 06.29.2010 03
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Marketing 105.53 Kb pdf

Description:

Remote Temperature Sensor Datasheet

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ProStar Operator’s Manual application/pdf English 08.19.2017 3.1
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Marketing 926.87 Kb pdf

Description:

Comprehensive manual covering installation, operation, and maintenance of the 2nd generation ProStar.

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ProStar Datasheet application/pdf English 02.10.2011 01
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Marketing 192.24 Kb pdf

Description:

Full operating specifications of the 2nd Generation ProStar including:

  • Electrical parameters
  • Mechanical specs
  • Environmental ratings

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Charging Isolated Battery Banks – 1 controller application/pdf English 09.29.2011 01
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Marketing 172.98 Kb pdf

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There is often a need to charge two or more isolated batteries with the same off-grid solar system. Morningstars SunSaver-Duo charge controller is designed to charge 2 isolated battery banks with an adjustable charging priority. We recommend the use of this controller for isolated battery bank applications.

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Charging with Parallel Controllers application/pdf English 05.13.2013 01
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Marketing 529.56 Kb pdf

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A diagram showing two SunSaver controllers shows how to properly parallel multiple Morningstar controllers into the same battery system. The concepts shown are applicable to all Morningstar controller models.

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Correct Inverter Wiring application/pdf English 05.13.2013 01
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Marketing 553.82 Kb pdf

Description:

A diagram shows how to properly wire a charge controller and an inverter into the same battery-based PV system.

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Declaration of Conformity for Products Under 48V application/pdf English 10.20.2011 01
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Marketing 256.14 Kb pdf

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The EMC Directive 2004/108/EC

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Load Control Using a Relay application/pdf English 05.13.2013 01
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Marketing 523.80 Kb pdf

Description:

Some loads are not suitable for direct connection to the Load terminals of a Morningstar controller. Heavily inductive or capacitive loads such as pumps, motors, compressors, and inverters should not be wired to the controllers Load terminals. In addition, loads exceeding the Load Current Rating of the controller should not be connected to the controllers Load terminals. Low Voltage Disconnect protection can be maintained when using these loads via the use of a Relay. A diagram and corresponding notes shows how this can be accomplished.

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Load Control w/ SureSine Inverter application/pdf English 05.13.2013 01
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Marketing 617.74 Kb pdf

Description:

Two diagrams are provided showing how load control can be safely used with inverters. The first diagram is applicable to all inverters. The second diagram is applicable to Morningstar SureSine inverters (and possibly 3rd party inverters with remote ON/OFF contacts). Note that in these diagrams, the TriStar Load Controller can be replaced with any Morningstar controller with Load Control functionality.

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Morningstar-Corporation-Traditional-PWM-vs-TrakStar-MPPT-Whitepaper-March-2015 application/pdf English 02.11.2014 01
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WHITEPAPER 1005.40 Kb pdf

Description:

A white paper discussing the advantages and disadvantages of PWM and MPPT charge controller technologies. Sizing, environmental, and cost factors are discussed.

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Parallel Battery String Wiring application/pdf English 05.28.2013 01
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Marketing 524.89 Kb pdf

Description:

A diagram shows how to correctly wire charge controllers to a battery bank comprised of multiple parallel strings. Correct wiring is important to ensure even and distributed charging of the entire bank.

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ProStar Bench Testing Instructions application/pdf English 10.03.2007 01
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Marketing 289.44 Kb pdf

Description:

Comprehensive testing instructions to verify operation of ProStar charge controller.
Test the controller using basic lab equipment:

  • power supply
  • small Ah battery
  • multimeter

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ProStar Electrical Diagram application/pdf English 07.28.2008 01
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Marketing 27.91 Kb pdf

Description:

Provides a high-level block diagram of the ProStar circuitry.

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ProStar Generations – Distinguishing Features application/pdf English 10.03.2007 01
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Marketing 154.05 Kb pdf

Description:

Pictures and a list of features that distinguish the 1st generation ProStar from the newer 2nd generation ProStar.

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ProStar Parallel Wiring application/pdf English 10.03.2007 01
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Marketing 22.22 Kb pdf

Description:

Wire multiple ProStars in parallel to expand charging capacity. This document shows wiring for two (2) ProStars wired in parallel on the same battery bank.

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ProStar Setpoints Summary application/pdf English 10.03.2007 02
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Marketing 53.08 Kb pdf

Description:

Quick view of the ProStar charging and protection setpoints.

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Title Type Language Date Version Rating
Audible buzzing noise during charging text/plain English 12.07.2009 01
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Tech Note 1.00 b txt

Description:

I sometimes hear a buzzing noise during charging. Is something wrong?

No. The buzzing sound is mechanical resonance created by the switching of current through the circuit board and solid-state devices. This is normal and not indicative of a problem.

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Calculating temperature compensated charging application/pdf English 05.17.2011 1
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Tech Note 191.23 Kb pdf

Description:

Here’s a brief explanation on how to calculate the temperature compensated adjustments our controllers make to their charging voltages based on the ambient temperature changes.

The charging voltages listed in the controller operator’s manual are specified at a 25C standard test condition ambient temperature with a -.030V (@ 12V battery) adjustment per degree C change in temperature above or below the 25C reference. The (-) in front of the .030V indicates that voltage adjustment is inverse to the change in temperature. In other words, if the temperature increases above 25C, the controller decreases it’s charging voltage by -.030V per degree C rise above 25C and vice versa. An accurate measurement of the ambient temperature is required for calculating the the controller’s temperature compensated adjustment.

Example:

An ambient temperature of 35C = +10C increase above the 25C base temp = 10 x -.030V compensated adjustment = temperature compensated -.300V decrease in charging voltage.
Therefore, a 14.4V charging voltage specified in the manual @ 25C would be reduced to 14.1V @ 35C or increased to 14.7V @ 15C.

The compensation rate is doubled to .060V/C for 24Vnominal battery systems and quadrupled to .120V/C for 48V nominal battery systems.

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Calculating temperature compensation variances application/pdf English 09.28.2011 01
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Tech Note 191.23 Kb pdf

Description:

How do I calculate the effect of temperature compensation on the regulation voltage?

Refer to the accompanying document download, which includes compensation curves for most Morningstar Controllers, or refer to temperature compensation coefficient in the specifications section of the Operator’s Manual.

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Can I mount the controller horizontally? text/plain English 05.12.2013 01
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Tech Note 1.00 b txt

Description:

Morningstar controllers have been designed to mount vertically. This is the orientation in which the heatsinks are most effective. Mounting the controller horizontally will reduce its passive cooling efficiency, but the risk of overheating will be determined by the ambient temperature and the power level at which the controller will be operating.

All efforts should be made to mount the controller vertically.

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Charge isolated battery banks with one controller application/pdf English 09.28.2011 01
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Tech Note 111.30 Kb pdf

Description:

Can I charge separate battery banks with one Morningstar charge controller?

Yes.  Refer to the document, “Charging Isolated Battery Banks – 1 Controller”.

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Charging Isolated Battery Banks – 1 Solar Array application/pdf English 09.29.2011 01
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Tech Note 48.64 Kb pdf

Description:

A wiring diagram for charging multiple isolated battery banks using multiple controllers and only one PV array.

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Charging LED staying lit after solar input removed text/plain English 05.12.2013 01
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Tech Note 1.00 b txt

Description:

Most Morningstar controllers will take up to 5 minutes to realize that the solar input voltage is no longer present before transitioning into the ‘night’ state. The controller performs periodic day/nigh checks (about once every 5 minutes). Depending upon where the controller is in this cycle when the input is removed, it may take anywhere from 0-5min for the controller to turn off its Charging LED and go into the ‘night’ state.

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Charging NiMh Batteries text/plain English 10.16.2007 01
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Tech Note 1.00 b txt

Description:

Our controllers are designed to charge lead-acid batteries which have different charging requirements than NiMh. Please DO NOT use our products with NiMh batteries, it is dangerous to do so.

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Common Reasons Why Power Transistors Fail text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

Description:

The internal switches of a controller, called MOSFETs or power transistors, switch current on and off to control solar current and load current. Because these components are in the power path, the controller will no longer be able to switch current if they fail.

Power transistors can fail for the following reasons:

  • Over-voltage: lightning or other high voltage transients on the PV power cables.
  • Over-current: too much PV for the controller or a short in the PV line pulls too much currentout of the battery through the controller.
  • Extreme temperatures during charging.
  • A premature failure of the component. The transistors are solid state devices that are manufactured in huge volumes with extremely low failure rates. However, no electrical components are 100% defect free and can pass test and then fail after a short period of time.
  • Old age

 

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Communication with the ProStar text/plain English 10.05.2007 01
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Tech Note 1.00 b txt

Description:

The ProStar does not support external communication. The ProStar meter option allows the user to view battery voltage, charge and load current, as well as self-diagnostic information. Other select Morningstar products offer communication using the open standard Modbus protocol.

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Controller System Sizing with 60 Cell Modules application/pdf English 10.01.2013 01
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Tech Note 290.20 Kb pdf

Description:

This Tech Tip discusses the use of today’s 60 cell PV modules with Morningstar’s solar controllers. It explains why 60 cell modules are not well adapted for meeting the nominal array voltage requirements of PWM controllers. It also shows how Morningstar’s MPPT controllers can be used with great success at higher input voltages.

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Do Morningstar controllers use SOC calculations? text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

Description:

Do Morningstar Controllers regulate according to SOC (State of Charge) calculations?

No. Morningstar Controllers regulate according to battery voltage setpoints. Because battery health and other factors affect charging over time, using voltage setpoints is a way to naturally track these changes and affords the user a complete understanding of the controllers operation. SOC calculations and algorithms may not be precise under all conditions and may leave the user with a “fuzzy” understanding of the workings of the unit.

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Green flashing LED with no solar input to controller text/plain English 09.13.2014 01
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Tech Note 34.00 b txt

Description:

If no input source (solar) is connected to the charge controller, but there are other charging sources connected to the batteries, charge controller may still show a Green Flashing LED (indicating that the controller is in the absorption charging stage). The Green Flashing LED may appear on the Morningstar controller if the battery voltage is at or above the controller’s Absorption charging voltage setting. Although the controller is not delivering power to the batteries (because there is no input source present), the indication still appears. This is not an indication of controller malfunction.

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Higher voltage array with a lower voltage battery text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

Description:

A higher voltage solar array (e.g. 24V nominal) can only be used with a lower voltage battery bank (e.g. 12V nominal) if the controller used is an MPPT controller.

PWM controllers CANNOT be used to charge a lower-voltage battery bank with a higher-voltage solar array. Please use an MPPT style controller if this is required.

 

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Noise or Interference During PWM Charging text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

Description:

Pulse Width Modulation (PWM) charging may cause interference in sensitive loads in the system during charging. The SunSaver switches current at 300 Hz. PWM switching noise can sometimes be heard in the controller itself, the wiring or wiring connections, or the system loads. AM radios and CB radios are especially prone to PWM interference. Noise in the controller or wiring is caused by mechanical resonance when current is switched through the circuits. There is little that can be done to remedy this issue. However, noise/interference in the system loads can usually be reduced or eliminated by the following:

1) Minimize cable runs between components

2) Twist power pairs(+/-) to reduce radiated noise

3) Good system grounding

4) Add capacitance across load power(at load input, 22000uf or more)

5) Add a line filter. some have had success with car audio filters that eliminate alternator whine. If these measures do not eliminate or reduce interference to acceptable levels, the controller can be modified to reduce the switching frequency. The 3rd generation SunSaver has a wire loop under the faceplate. If this loop is cut, the controller will reduce the switching frequency to ~1 Hz. Refer to the SunSaver Operator’s Manual for more information.

6) Some Morningstar controllers allow for operation in a ‘low-noise’ state. Check your controller documentation for details.

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Parallel load outputs of multiple controllers text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

Description:

The load outputs of multiple charge controllers can be wired together in parallel provided the following is true:

  • The total load draw does not exceed the current rating of the LOWEST RATED CONTROLLER
  • Isolating diodes are installed on each of the controller’s load outputs (if the controllers to not share a battery bank)

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ProStar E07 Self-diagnostics error text/plain English 10.05.2007 01
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Tech Note 1.00 b txt

Description:

If the ProStar self-diagnostics check returns an “E07” error, check the following:

  • Disconnect the Load connections at the ProStar and re-run the self test. Does the error still persist? If the error persists, the power transistors in the load control are damaged.
  • Check your wiring. Make sure that the only power feed to your loads is from the ProStar Load connection. If the battery is also directly wired to your loads, this is the reason for the error.
  • If you have not already done so, add a diode across the Load terminals on the ProStar to clamp inductive spikes. You have motor loads which can damage the ProStar overtime. A normal recovery diode with a forward current rating equal to or greater than the inductive load current, cathode to Load+, anode to Load – will suffice.

 

Note: If other errors in addition to E07 are reported, there may be a combination of issues or failures.

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ProStar Load Guidelines text/plain English 10.05.2007 01
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Tech Note 1.00 b txt

Description:

Here are a few guidelines concerning DC loads and the ProStar:

1) Do not wire inverters of any size to the ProStar

2) The total load draw should not exceed the load current rating (ProStar 30 = 30A max load draw)

3) Inductive loads such as pumps, motors, fridge compressors – should have a clamping diode* installed to protect the ProStar switching circuit

4)The load lines should be fused for best protection.

 

*The diode should be placed across the Load terminals on the ProStar with the cathode of the diode on Load +. The forward current rating of the diode should be equal to or greater than the peak load current draw.

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ProStar meter display malfunctioning text/plain English 12.23.2008 01
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Tech Note 1.00 b txt

Description:

Problem: The ProStar meter display is blank, displays nonsensical characters, or is frozen. In many cases, the LEDs and/or buttons are frozen.

Solution: In most cases, the 6-pin connector between the main controller board and the meter board is damaged or corroded.
If the ProStar is within the 5 year warranty period, contact your dealer for warranty service.

Out of warranty repair procedure (requires soldering skills):

  • disconnect all wires from the ProStar
  • Remove the four screws securing the plastic cover, remove the cover.
  • inspect the 6-pin connectors on the main board and meter board for breaks, corrosion, debris
  • with a fine tip solder iron, reflow any broken solder joints. Clear any debris. Clean corrosion with a Q-tip and rubbing alcohol.

 

Note: the push-button should “click” when pressed. If the button feels stuck, remove the clear plastic cap and gently bend the LED legs upwards so that the body of the switch can return to rest position. Replace the plastic cap.

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ProStar meter display not working / showing strange values text/plain English 09.13.2014 01
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Tech Note 34.00 b txt

Description:

If the ProStar meter shows strange characters on the display, check the battery voltage to ensure that it is above 8V. If the battery voltage falls below about 8V, the controller’s circuitry goes into a ‘brown-out’ condition. In this state, the processor behavior may be erratic and the meter display may not work correctly. The controller’s LEDs may also operate erratically in this state.

Correct the problem by charging the battery bank directly or with another charger until it is solidly above 8V.

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ProStar R-G-R-G LED Error Indication text/plain English 11.02.2012 01
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Tech Note 1.00 b txt

Description:

The flashing R-G-R-G LEDs indicate a high voltage disconnect (HVD) condition. If you have other charging sources in the system, they may be charging the battery above the ProStar’s regulation set-point, causing the high voltage indication. If battery voltage remains within the ProStar’s safe operating range, the ProStar will not be damaged. The indication will clear when battery voltage has returned to normal. The ProStar will clear the Load HVD at 14.5V (29V for a 24V nominal system) and will clear the Array/Charging HVD at 12.3V (24.6V for a 24V system).

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ProStar Solar Input Voltage Specifications text/plain English 05.13.2013 01
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Tech Note 1.00 b txt

Description:

The maximum input voltage rating for the ProStar is 58 Vdc.
If using the ProStar to charge a 12 Volt battery, the input must be a nominal 12 Volt off-grid solar panel with a Voc < 30 Volts.

Do not charge a 12 Volt battery with a 24 V solar panel. The solar panel will operate too far off its power point (very inefficient) and voltage spikes during regulation will damage the ProStar.

Damage resulting from an array >30Voc in a 12V battery bank system will NOT be covered under warranty.

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Purpose of the battery sense connection text/plain English 12.11.2007 01
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Tech Note 1.00 b txt

Description:

When large currents flow through the battery power cables, a voltage drop results due to resistance in the cables. Since the controller regulates the batteries according to battery voltage, it is important that the controller measure the voltage directly at the battery. The Battery Sense connection allows battery voltage measurement directly at the terminals because the sense lines carry very little current (hence, small-gauge wire) enabling accurate regulation.   Without the sense lines, the controller must use the battery power connections, which may be different than actual battery voltage. The Battery Sense connection is optional and is only needed when significant voltage drops exist on the battery power cables.

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Reverse discharge protection at night text/plain English 09.12.2014 01
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Tech Note 34.00 b txt

Description:

All Morningstar controllers will automatically prevent reverse discharge of the battery back through the solar array during the night. No external diodes on the input of the controller are required.

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Should I add fuses and/or disconnects to my system? text/plain English 12.13.2007 01
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Tech Note 1.00 b txt

Description:

Fuses, circuit breakers and disconnects should be included in your system. Refer to your local/national codes concerning requirements. The controller’s Operation Manual outlines NEC requirements for installations in the United States.

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Using a DC power supply as a PV panel substitute? text/plain English 03.05.2009 01
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Tech Note 1.00 b txt

Description:

Can I use a power source other than a PV panel to charge my batteries?

We do not recommend using a DC power supply with any of our PWM controllers. While they appear to be similar to PV modules in function, DC power supplies have considerably more output capacitance. Connecting a DC power supply to our PWM controllers may cause excessive heating and premature failure. MPPT controllers can be used for this purpose without issue. In addition, AC powered battery chargers are often the best option for systems requiring AC battery charging.

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Using multiple controllers with one PV array application/pdf English 09.28.2011 01
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Tech Note 71.50 Kb pdf

Description:

Can I wire multiple controllers in parallel off the same PV array to charge different batteries?

Yes. Refer to the document, “Charging Isolated Battery Banks”. This can ONLY be done with PWM controllers. MPPT controllers cannot be used in this configuration.

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What caused my controller terminal to burn/melt? text/plain English 09.12.2014 01
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Tech Note 34.00 b txt

Description:

When two conductors (a wire and screw terminal for instance) are mated, there is a resistance at that connection. Usually this contact resistance is very low and poses no threat. However, when connections become loose, oxidation builds on the surfaces, or corrosion accumulates, the resistance at the connection can increase to a dangerous level.

When current passes through resistance, power is dissipated in the form of heat. If the value of the resistance goes up, so does the power dissipated (for the same amount of current). When a connection has high resistance, the heat generated at the connection can melt surrounding material such as plastics and actually catch fire.

Resistive connections can occur on any electronic device that carries significant amounts of power. It is important to periodically check the tightness of the connections and inspect for corrosion as suggested in the Maintenance section of the Operator’s Manual. Along with periodically checking the connections, dielectric grease can be applied to the terminals to avoid corrosion build-up on the conductor surfaces. Mobile installations tend to be the most susceptible to developing resisitve connections because motion works cables loose from their terminals, however, resistive connections can occur on stationary installations as well.

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What is PWM charging? application/pdf English 12.11.2007 01
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Tech Note 313.43 Kb pdf

Description:

PWM is an acronym for Pulse Width Modulation. When the battery is recharged to regulation voltage, the controller will begin limiting the amount of current into the battery so that the regulation voltage is maintained but not surpassed. The method of regulating the current, referred to as PWM, pulses current into the battery with pulses of a varying width. Wider pulses allow a greater percentage of the input current to flow into the battery, narrower pulses restrict current to a lower percentage. Refer to the accompanying download,  “Why PWM?”, for more technical and detailed information concerning PWM charging.

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What is the purpose of the Load connection? text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

Description:

The Load connection allows the user to wire DC devices such as fans, bulbs, or communication equipment directly to the controller. This allows the controller to disconnect the loads if necessary for protection of the controller, battery, or the loads themselves. This connection is optional and, as an alternative, the system loads can be wired directly to the battery bank.

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What is the PWM switching frequency? text/plain English 05.13.2013 01
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Tech Note 1.00 b txt

Description:

All Morningstar PWM type controllers have a PWM switching frequency of ~300Hz.

Some Morningstar PWM controllers have a feature which will reduce the switching frequency to ~1Hz (called on/off charging). This on/off charging virtually eliminates switching noise (both radiated and conducted) and can be used when experiencing noise problems with 300Hz switching operation.

Current models with this on/off charging option are:

– SunSaver Generation 3

– SunSaver Duo

– ProStar PWM

– TriStar PWM

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Why PWM? application/pdf English 11.07.2012 01
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Tech Note 231.60 Kb pdf

Description:

Frequently Asked Questions about PWM battery charging are addressed.

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Will other charging sources backfeed into my controller? text/plain English 09.12.2014 01
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Tech Note 34.00 b txt

Description:

Other charging sources can be used in parallel with the Morningstar charge controller; you do not need to isolate the controller from the battery. For best performance when using other charging sources, ensure the charging source and Morningstar controller are set to charge to the same (or close) voltage. If the supplemental charging source is set to a higher charging voltage than the Morningstar controller, the Morningstar controller may go into a fault state temporarily when the battery voltage rises higher than the controller’s setpoint. The controller will automatically recover from this state when the battery voltage drops to a lower level.

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Wiring an inverter to controller Load output text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

Description:

We do not recommend wiring inverters to the load terminals of our products because of current in-rush on start up. Inverters typically have large amounts of input capacitance (for input filtering). When power is first applied, these capacitors can draw very large currents in the 100’s of amps, albeit for a short period of time. These current surges can stress our power transistors and will trip our short circuit protections. The inverter may start eventually after several attempts to reconnect from the short circuit condition, but this mode of operation is not normal. For this reason, we do not recommend wiring inverters directly. Many inverters have their own LVD circuitry and will not allow the battery to discharge too low. However, if the customer requires load control and LVD functionality, they can switch the inverter through a relay wired in series between the battery and inverter.

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Wiring multiple controllers to one battery bank? text/plain English 12.10.2007 01
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Tech Note 1.00 b txt

Description:

Yes. There can be as many Morningstar controllers as required in parallel on the same battery bank. For best performance, set each controller to as close a charge setting as possible. Since the controllers will not have direct communication with each other, it is not unusual to see the controllers transition between charging stages at different times. This is generally not a concern.

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Title Type Language Date Version Rating
ProStar Sleeve image/png English 07.02.2014 01
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Image 17.03 Mb png

Description:

Photo of ProStar product sleeve

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Title Type Language Date Version Rating
2014-2015 Product Catalog in English application/pdf English 05.14.2014 01
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Corporate 4.70 Mb pdf

Description:

The 2014/2015 Morningstar Product Catalog in English

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Company Profile (video) video/x-ms-wmv English 10.16.2012 01
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Corporate 70.29 Mb wmv

Description:

Short video highlighting Morningstar Corporation’s history and products.

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Counterfeit Campaign application/pdf English 04.16.2013 01
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Corporate 136.83 Kb pdf

Description:

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Intl-Warranty application/pdf English 10.17.2013 01
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Corporate 98.02 Kb pdf

Description:

Morningstar Product Warranty

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RoHS Certification Document application/pdf English 02.19.2014 01
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Corporate 81.08 Kb pdf

Description:

The part numbers listed within are in compliance with Directive 2011/65/EC on the restriction of the use of certain
hazardous substances in electrical and electronic equipment (RoHS directives). This document also certifies that
the product declaration that has been provided by Morningstar Corporation is accurate.

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Strong R&D Capability and Engineering Excellence application/pdf English 08.02.2013 01
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Corporate 119.38 Kb pdf

Description:

Whitepaper on Morningstar’s s high-level of innovation, R&D and engineering excellence.

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Tech Support Policy application/pdf English 09.11.2014 01
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Corporate 76.48 Kb pdf

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Warranty Claim Procedure application/pdf English 09.11.2014 01
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Corporate 97.76 Kb pdf

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Weights and Dims application/pdf English 12.16.2015 02
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Corporate 289.03 Kb pdf

Description:

PDF file of the packed Weights and Dims of Morningstar products.

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