MORNINGSTAR 5662252419082 Solar Charging System Controller User Guide

: June 6, 2024
: Morningstar

Table of Contents

5662252419082 Solar Charging System Controller
2
2 Philips Screwdriver
Read User Manual Online (PDF format)
Download This Manual (PDF format)

5662252419082 Solar Charging System Controller

Specifications:
Nominal Battery Voltage Max. PV Open-Circuit Voltage
Maximum Input Current Rated Load Current

PS-15/PS-15M 12/24 V 30/60 V 15 A 15 A

PS-30/PS-30M 12/24 V 30/60 V 30 A 30 A

Operational Configuration:

Warning: Shock Hazard
Test between all terminals and ground before touching.
Power or accessory terminals are NOT electrically isolated from DC input and may be energized with hazardous solar voltage.

Switch 1: Load/Lighting

Switches 2 & 3: System Voltage

Mode Normal Lighting

Switch 1 OFF ON

Normal

Lighting

System Voltage Auto 12 24

Switch 2 OFF OFF ON

Switch 3 OFF ON OFF

AUTO

12 V

Switches 4, 5, & 6: Battery Type Selection

NOTE: The ProStar Gen3 can be programmed to accommodate a wide range of charging parameters. Consult the battery manufacturer for optimal battery charging settings.

24 V

To Change Settings: · On metered models, use the interface on the meter or use the software available at https://www.morningstarcorp.com/msview/. · On non- metered models, use the software available at https://www.morningstarcorp.com/msview/.

See the ProStar Installation, Operations, and Maintenance Manual for additional information/guidance.

1 Sealed *

2 Sealed *

3 Sealed *

4 AGM / Flooded *

5 Flooded

6 Flooded

7 L-16

Custom**

DIP Switch Setting
4 5 6

Battery Type

Absorption Float Equalize Absorption

Stage

State Stage

Time

(Volts) (Volts) (Volts) (Minutes)

Equalize Time
(Minutes)

Equalize Timeout (Minutes)

Equalize Interval (days)

LVD (Volts)

OFF OFF OFF 1 Sealed*

14.00

13.50

—

150

—

11.5

OFF OFF ON 2 Sealed*

14.15

13.50 14.40

150

60

120

28

11.5

OFF ON OFF 3 Sealed*

14.30

13.50 14.60

150

60

120

28

11.5

OFF ON ON 4 AGM/Flooded* 14.40

13.50 15.10

180

120

180

28

11.5

ON OFF OFF 5 Flooded

14.60

13.50 15.30

180

120

180

28

11.5

ON OFF ON 6 Flooded

14.70

13.50 15.40

180

240

28

11.5

ON ON OFF 7 L-16 ON ON ON 8 Custom**

15.40 Custom

13.40 16.00 Custom Custom

180 Custom

240 Custom

14 Custom

11.5 Custom

*”Sealed” battery types include Gel and AGM Batteries

**Lithium-ion and some other battery types require custom programming. Morningstar provides downloadable settings for selected battery manufacturers here: https://www.morningstarcorp.com/energy-storage-partner-program/

LVR Volts)
12.6 12.6 12.6 12.6 12.6 12.6 12.6 Custom

Shared Settings Absorption Extension Voltage
Absorption Extension Time Float Exit Time-Out

Set Point 12.50 Volts Absorption Time +30 minutes 30 minutes

Shared Settings Float Cancel Voltage Equalize Time-Out Temperature Compensation Co-Efficient

Set Point 12.10 Volts Equalize Time +60 minutes 30 millivolts / °C / 12 Volts

Switch 7: Battery Equalization

Mode Manual Equalization
Auto-Equalization

Switch 7 OFF ON

Manual EQ

Auto EQ

Switch 8: Current Switching

Mode PWM Switching Slow Switching

Switch 8 OFF ON

PWM Switching Slow Switching

Contact Information:
Technical Support: Support.morningstarcorp.com Phone: 1-215-321-4457
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Quick Start Guide

Safety Information:

Warning: Shock Hazard
The ProStar Gen3 controller must be installed by a qualified technician in accordance with the electrical regulations of the country of installation.

Metered version shown.
Scan QR Code to go directly to the ProStar Gen3 Installation Manual and warranty information online.

Warning: Shock Hazard 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.
IMPORTANT: READ the ProStar Gen 3 Installation Manual for safety and regulatory information, instructions on configuration and operation, and warranty information.

Warranty Registration: https://www.morningstarcorp.com/product-registration/

In the box:

Optional Accessories

ProStar Charge Controller

Self-Tapping Mounting
Screws (x4)

Menu Map (2 pages)

Tools Required:
— #2 Philips Screwdriver — 3/16 (5 mm) & 3/32″ (2.5 mm) Flathead Screwdriver

Remote Meter (RM-1)

Relay Driver (RD-1)

Remote Temperature Sensor (RTS)

Ethernet MeterBus Converter (EMC-1)

USB Communications Adapter (UMC-1)

PC MeterBus Adapter (MSC)

PV Ground Fault Protection (GFPD-150V and GFPD-600V)
1

ProStar Gen3 Charge Controller

Quick Start Guide

Caution: Equipment Damage
Do not expose the ProStar CC to weather. Locate in a dry, protected area to prevent equipment damage. Ensure the minimum clearance requirements are followed to provide adequate ventilation and prevent the unit from overheating.

6″

2″

Minimum

6″

Clearance Requirements

Mounting:

IMPORTANT: Mount in the orientation shown here with the heat sink fins vertical.

Photovoltaic (PV) Array See the Morningstar PV String Calculator at: http ://string-calculator.morningstarcorp.com/
() (+)

Charging Status/
Error LED

SOLAR

Battery Status/ Fault LEDs

BATTERY

ON

DIP

1 2 3 4 56 78
SENSE RTS

LOAD

DIP Switch Block (enlarged)
(See Page 4 for settings)
12345678

IMPORTANT: Example only. Actual wiring may vary. READ the ProStar Gen3 Installation, Operations, and Maintenance Manual for mandatory safety requirements. All configuration must comply with local and national electric codes. Consult your local electric authority to ensure compliance.
This illustration represents a typical off-grid installation. For use with an inverter, refer to the inverter’s installation manual for additional information.
LED Indicators: See the ProStar Gen3 Installation Manual for details.

DC Load(s)*

Solar Disconnect*
(PV GFP required per NEC 690)
RJ-11 Cable

DC Load Disconnect*

Residential

Industrial

Communications Lighting Security

(–) Voltage Sense Conductor

Remote Temperature Sensor Conductor

SOLAR

BATTERY

ON
1 2 3 4 56 78
SENSE RTS

LOAD

1

Push tabs outward to release the terminal cover.

Pull the terminal cover

Top

2

forward to remove it.

SOLAR

BATTERY

ON
1 234 56 78
SENSE RTS

LOAD

Bottom

Tighten the 4 self-tapping

3

screws just enough to

hold the ProStar in place.

2

IMPORTANT: Do NOT over tighten.

2

Optional Accessories

Remote Meter Ethernet MeterBus Converter

Relay Driver

USB Communications Adapter (UMC-1)

PC MeterBus Adapter (MSC)

Battery (+)

Battery ()

(+) Voltage Sense

Fuse

Conductor

Battery Disconnect*
6″ (15 cm) MAXIMUM Distance from Battery (+) Terminal

Securing hardware not shown.

(+)

()

Battery / Battery Bank

Wiring and Torque Requirements

Component

Wire Size

Tool Required

Power Terminals
Battery Voltage Sense
Remote Temperature Sensor

2.5 – 16 mm2 / #14 – 6 AWG 0.25 – 1.0 mm2 / #24 – 16 AWG
(included)

3/16″(5 mm) Flathead Screwdriver
3/32″ (2.5 mm) Flathead Screwdriver
3/32″ (2.5 mm) Flathead Screwdriver

Torque (Max) 35 in-lbs. (3.9 Nm) 5 in-lbs. (0.56 Nm) 5 in-lbs. (0.56 Nm)

Mounting Screws

—

2 Philips Screwdriver

5 in-lbs. (0.56 Nm)

LEGEND
Negative ()
Positive (+) Ground
*Fuse or breaker sizing based on required wire ampacity

Power UP Sequence: 1. Connect Battery/Battery Bank. 2. Connect Solar. Power DOWN Sequence: 1. Disconnect Solar. 2. Disconnect Battery/Battery Bank.

DC-to-Ground Bond
Primary Ground Electrode Conductor
(System Ground) IMPORTANT: Ensure there is only 1 DC Negative-to-Ground Bond in the entire system.
3