TM

ProStar MPPT
Solar Charging System Controller
Installation, Operation and Maintenance Manual
For the most recent manual revision, see the version at:
www.morningstarcorp.com

www.morningstarcorp.com

MODELS

PS-MPPT-25
PS-MPPT-25M
PS-MPPT-40
MAXIMUM POWER POINT TRACKING
PS-MPPT-40M
 DIMENSIONS [inches (centimeters)]
TABLE OF CONTENTS
7.88
( 20.0 )
6.69 1.0 Important Safety Instructions............................. 1
( 17.0 )
2.0 General Information..... .................................... ..10
2.1 Overview................................................................10
2.2 Regulatory Information........................................11
7.62
6.69
4.92
( 12.5 )
( 19.4 ) 2.3 Versions and Ratings................................................13
( 17.0 )
2.4 Features.................................................................14
2.5 Optional Accessories..............................................16
3.0 Installation.............................................................18
3.1 General Installation Notes......................................18
3.2 Configuration.........................................................21
3.3 Mounting...............................................................23
2.76
3.4 Wiring...................................................................25
( 7.0 )
4.0 Operation..............................................................36
4.1 TrakStar MPPT Technology....................................... 36
4.2 Battery Charging Information...................................38
SPECIFICATION SUMMARY 4.3 Load Control Information........................................ 48
PS-MPPT-25 PS-MPPT-40 4.4 LED Indications......................................... .... ....... .50
4.4.1 Power-up............................................................... .50
Nominal Battery 12/24V 12/24V
Voltage 4.4.2 Status LED.............................................................. 50
4.4.3 State-of-charge LEDs...............................................51
Max. PV Open- 120V 120V
Circuit Voltage* 4.5 Push-button Use in Non-Metered Version.............51
Nominal Max. Input 560 / 4.6 Alarms......................................................................52
Power** 350 / 700W
1120W 4.7 Custom Settings............................. ........................54
Max. Battery 25A 40A 4.7.1 Programming with Meter Display........................... 54
Charging Current
4.7.2 Programming in MSView.........................................55
Rated Load Current 25A 30A 4.7.3 Meter Display Operation.........................................55
*Array voltage should never exceed this limit 4.7.3.1 Directional Key Use and Operation / Navigating
the Meter Map.......................................................55
**These power levels refer to the maximum wattage the PS-MPPT 4.7.3.2 Adjusting the Meter Display...................................56
can process. Higher power arrays can be used without damaging the
4.7.4 Using the Meter Display to Program Charging
controller.
Set-points, Load Control, Communications, and
Advanced Settings....................................................56

ii ProStar MPPT Operator’s Manual ProStar MPPT Operator’s Manual iii

4.7.5 Lighting Control / Programming Overview...............56 1.0 IMPORTANT SAFETY INSTRUCTIONS

1.0
4.7.6 Lighting Programming Using Meter Display............. 57
4.7.7 Low Temperature Foldback.......................................57 SAVE THESE INSTRUCTIONS.
4.8 Inspection and Maintenance..................................... 58
This manual contains important safety, installation, operating
5.0 Troubleshooting...........................................60 and maintenance instructions for the ProStar MPPT solar
5.1 LED Fault Indications.................................................. .60 controller.
5.2 Battery Charging and Performance Issues..................65 The following symbols are used throughout this manual to
6.0 Warranty and Policies..................................66 indicate potentially dangerous conditions or mark important
safety instructions:
7.0 Technical Specifications............................... 70  WARNING: Indicates a potentially dangerous condition.
Appendix A - Efficiency.........................................73 Use extreme caution when performing this task.

Appendix B - De-rating Graphs.......................... 75 CAUTION: Indicates a critical procedure for safe and
 proper operation of the controller.
Appendix C - Wire Sizing Charts............................ 77
NOTE: Indicates a procedure or function that is important
CERTIFICATION ADDENDUM  to the safe and proper operation of the controller.
TO OPERATOR’S MANUAL 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.

iv ProStar MPPT Operator’s Manual ProStar MPPT Operator’s Manual 1

Safety Information AVERTISSEMENT: Risque De Choc Électrique.

1.0
NON ALIMENTATION OU AUX BORNES
• Read all of the instructions and cautions in the manual
D'ACCESSOIRES SONT ISOLÉS ÉLECTRIQUEMENT DE
before beginning installation.
L'ENTRÉE DE C.C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION
• There are no user serviceable parts inside the DANGEREUSE SOLAIRE. SOUS CERTAINES CONDITIONS
ProStar MPPT. Do not disassemble or attempt to repair DE DÉFAILLANCE, LA BATTERIE POURRAIT DEVENIR TROP
the controller. CHARGÉE. TEST ENTRE TOUTES LES BORNES ET LA MASSE
AVANT DE TOUCHER.
WARNING: Risk Of Electrical Shock.
NO POWER OR ACCESSORY TERMINALS ARE
AVERTISSEMENT: LE PORT DE COMMUNICATION EST
ELECTRICALLY ISOLATED FROM DC INPUT, AND MAY BE
CONSIDÉRÉE COMME DVC B. UN ISOLATEUR EXTERNE
ENERGIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER N'EST NÉCES SAIRE SI C'EST D'ÊTRE CONNECTÉ À UN DVC
CERTAIN FAULT CONDITIONS, BATTERY COULD BECOME UN CIRCUIT.
OVER-CHARGED. TEST BETWEEN ALL TERMINALS AND
GROUND BEFORE TOUCHING. • External solaire et la batterie se déconnecte sont
nécessaires.
WARNING: THE COMMUNICATIONS PORT IS
• Déconnectez toutes les sources d’alimentation du
CONSIDERED TO BE DVC B. AN EXTERNAL
ISOLATOR IS REQUIRED IF IT IS TO BE CONNECTED TO A DVC contrôleur avant d’installer ou de régler le ProStar MPPT.
A CIRCUIT. • Le ProStar MPPT MPPT ne contient aucun fusible ou
• External solar and battery disconnects are required. interrupteur. Ne tentez pas de réparer.
• Disconnect all sources of power to the controller before • Installez des fusibles/coupe-circuits externes selon le
installing or adjusting the ProStar MPPT. besoin.
• There are no fuses or disconnects inside the ProStar MPPT
Do not attempt to repair. Installation Safety Precautions

Informations de Sécurité WARNING: This unit is not provided with a GFDI device.
• Lisez toutes les instructions et les avertissements figurant This charge controller must be used with an external
GFDI device as required by the Article 690 of the
dans le manuel avant de commencer l’installation. National Electrical Code for the installation location.
• Le ProStar MPPT ne contient aucune pièce réparable par
l’utilisateur. Ne démontez pas ni ne tentez de réparer le
contrôleur. • 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.

2 Important Safety Instructions ProStar MPPT Operator’s Manual 3

• The battery bank must be comprised of batteries of same A permanent, reliable earth ground must be established
type, make, and age.

1.0
with connection to the ProStar MPPT ground terminal.
• UL/IEC 62109 certified for use in negative ground or The grounding conductor must be secured against any
floating systems only. accidental detachment.
• Do not smoke near the battery bank.
• Power connections must remain tight to avoid excessive Précautions de Sécurité D’installation
heating from a loose connection.
• Use properly sized conductors and circuit interrupters. AVERTISSEMENT: L’appareil n’est pas fourni avec un
• The grounding terminal is located in the case, and is dispositif GFDI. Ce contrôleur de charge doit être
identified by the symbol below: utilisé avec un dispositif GFDI externe tel que requis
par l’Article 690 du Code électrique national de
l’emplacement de l’installation.
• 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 Pro-

Ground Symbol Star MPPT peut devenir très chaud pendant le fonc-
tionnement.
• This charge controller is to be connected to DC circuits
only. These DC connections are identified by the symbol • Utilisez des outils isolés pour travailler avec les batteries.
below: • 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.
Direct Current Symbol
• Ne fumez pas à proximité du groupe de batteries.
The ProStar MPPT controller must be installed by a qualified • Les connexions d’alimentation doivent rester serrées
technician in accordance with the electrical regulations of pour éviter une surchauffe excessive d’une connexion
the country of installation. desserrée.
A means of disconnecting all power supply poles must be • Utilisez des conducteurs et des coupe-circuits de dimen-
sions adaptées.
provided. These disconnects must be incorporated in the
fixed wiring. • La borne de mise à la terre se trouve dans l'affaire et est
identifié par le symbole ci-dessous :
The ProStar MPPT negative power terminals are common,
and must be grounded as instructions, local codes, and
regulations require.

4 Important Safety Instructions ProStar MPPT Operator’s Manual 5

• Ce contrôleur de charge ne doit être connecté qu’à WARNING: Risk of Explosion.
Proper disposal of batteries is required. Do not

1.0
des circuits en courant continu. Ces connexions CC sont
identifiées par le symbole ci-dessous: 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
Le régulateur MPPT ProStar doit être installé par un specified number, sizes, types, and ratings based on
technicien qualifié conformément aux règlements du pays application and system design.
d'installation électriques.
PRUDENCE: Lorsque le remplacement des piles,
Un moyen de déconnexion de tous les poteaux utilisez correctement nombre spécifié, tailles, types et
d'alimentation doit être fourni. Ceux-ci se déconnecte doit les évaluations basées sur conception de système et
être intégrée dans le câblage fixe. d'application.
CAUTION: Do not open or mutilate batteries.
Une mise à la terre permanent et fiable s'impose avec Released electrolyte is harmful to skin, and may be
raccordement à la borne ProStar MPPT. toxic.
Les bornes de puissance négative ProStar MPPT sont com- PRUDENCE: Ne pas ouvrir ou mutiler les piles.
muns et doivent être mise à la terre comme les directives, les L'électrolyte est nocif pour la peau et peut être
codes locaux, et les règlements exigent. toxique.
• Servicing of batteries should be performed, or supervised,
Le conducteur de terre doit être protégée contre tout dé-
by personnel knowledgeable about batteries, and the
tachement accidentel.
proper safety precautions.
Battery Safety •  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.
WARNING: A battery can present a risk of electrical
shock or burn from large amounts of short-circuit • Remove watches, rings, jewelry and other metal objects
current, fire, or explosion from vented gases. before working with batteries.
Observe proper precautions. • Wear rubber gloves and boots
AVERTISSEMENT: Une batterie peut présenter a ris • Use tools with insulated handles and avoid placing tools
que de choc électrique ou de brûlure de grandes or metal objects on top of batteries.
quantités de court-circuit curlouer, incendie ou • Disconnect charging source prior to connecting or
explosion de ventilé gaz. Observer précautions disconnecting battery terminals.
appropriées.

6 Important Safety Instructions ProStar MPPT Operator’s Manual 7

• Determine if battery is inadvertently grounded. If so, • Débrancher la source de charge avant de brancher ou
remove the source of contact with ground. Contact with dis-reliant les bornes de la batterie.

1.0
any part of a grounded battery can result in electrical • Utilisez des outils isolés et évitez de placer des objets
shock. The likelihood of such a shock can be reduced métalliques dans la zone de travail.
if battery grounds are removed during installation and • Déterminer si batterie repose par inadvertance. Dans
maint​enance (applicable to equipment and remote l'affirmative, supprimer la source du contact avec le sol.
battery supplies not having a grounded supply circuit). Contact avec n'importe quelle partie d'une batterie mise
• Carefully read the battery manufacturer's instructions à la terre peut entraîner un choc électrique. La probabilité
before installing / connecting to, or removing batteries d'un tel choc peut être réduite si des motifs de batterie
from, the ProStar MPPT. sont supprimés pendant l'installation et maintentretien
• Be very careful not to short circuit the cables connected (applicable à l'équipement et les fournitures de pile de la
to the battery. télécommande n'ayant ne pas un circuit d'alimentation
• Have someone nearby to assist in case of an accident. mise à la terre).
• Explosive battery gases can be present during charging. • Lisez attentivement les instructions du fabricant de la
Be certain there is enough ventilation to release the batterie avant d'installer / connexion à ou retrait des
gases.
batteries du ProStar MPPT.
• Never smoke in the battery area. • Veillez à ne pas court-circuiter les câbles connectés à la
• If battery acid comes into contact with the skin, wash batterie.
with soap and water. If the acid contacts the eye, flood • Ayez une personne à proximité qui puisse aider en cas
with fresh water and get medical attention. d’accident.
• Be sure the battery electrolyte level is correct before starting • Des gaz explosifs de batterie peuvent être présents
charging. Do not attempt to charge a frozen battery. pendant la charge. Assurez-vous qu’une ventilation
• Recycle the battery when it is replaced. suffisante évacue les gaz.
• Ne fumez jamais dans la zone des batteries
• En cas de contact de l’électrolyte avec la peau, lavez avec
• Entretien des batteries devrait être effectué ou super- du savon et de l’eau. En cas de contact de l’électrolyte
visé, par un personnel bien informé sur les piles et les avec les yeux, rincez abondamment avec de l’eau fraîche
précautions de sécurité appropriées. et consultez un médecin.
• Soyez très prudent quand vous travaillez avec des • Assurez-vous que le niveau d’électrolyte de la batterie est
grandes batteries au plomb. Portez des lunettes de correct avant de commencer la charge. Ne tentez pas de
protection et ayez de l’eau fraîche à disposition en cas de charger une batterie gelée.
contact avec l’électrolyte.
• Recyclez la batterie quand elle est remplacée.
• 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.

8 Important Safety Instructions ProStar MPPT Operator’s Manual 9

2.0 GENERAL INFORMATION 2.2 Regulatory Information
2.1 Overview NOTE: This section contains important
information for safety and regulatory
Thank you for choosing the ProStar MPPT charge controller requirements.
with TrakStarTM MPPT Technology. The ProStar MPPT is an

2.0
advanced maximum power point tracking solar battery FCC requirements:
charger. The controller features a smart tracking algorithm This device complies with Part 15 of the FCC rules.
that finds and maintains operation at the power source's Operation is subject to the following two conditions:
peak power point, maximizing energy harvest. (1) This device may not cause harmful interference,
The ProStar MPPT battery charging process has been and,
optimized for long battery life and improved system (2) this device must accept any interference
performance. Self-diagnostics and electronic error received, including interference that may cause
protections prevent damage when installation mistakes or undesired operation.
system faults occur. The controller also features eight (8)
adjustable settings switches, several communication ports, Changes or modifications not expressly approved
by Morningstar for compliance could void the user’s
and terminals for remote battery temperature and voltage
authority to operate the equipment.
measurement. 
Please take the time to read this operator’s manual to NOTE: This equipment has been tested and found
become familiar the many benefits the ProStar MPPT can  to comply with the limits for a Class B digital
provide for your PV systems, for example: device, pursuant to Part 15 of the FCC rules. These limits
are designed to provide reasonable protection against
• Rated for 12 or 24 volt systems, and 25 or 40 amps of
charging current harmful interference in a residential installation. This
• Fully protected with automatic and manual recovery equipment generates, uses, and can radiate radio
• Seven standard charging programs selectable with DIP frequency energy and, if not installed and used in
switches accordance with the instruction manual, may cause harmful
• Continuous self-testing with fault notification interference to radio communication. However, there is no
• LED indications and push-button or meter key functions guarantee that interference will not occur in a particular
installation.
• Terminals sized for #2 AWG (35mm2) wire - compliant
when used with the optional Morningstar Wire Box, If this equipment does cause harmful interference to radio
otherwise a maximum of #6 AWG wire. or television reception, which can be determined by
• Includes battery voltage sense terminals turning the equipment on and off, the user is encouraged
• Digital meter display options to try to correct the interference by one or more of the
• Optional remote battery temperature sensor following measures:
• 5-year warranty (see Section 6.0)

10 General Information ProStar MPPT Operator’s Manual 11

• Re-orient or relocate the receiving antenna. 2.3 Versions and Ratings
• Increase the separation between the equipment and
receiver.
• Connect the equipment into an outlet on a circuit PS-MPPT-25
different from that to which the receiver is connected. • Rated for maximum 25 amps continuous current
(battery or load)

2.0
• Consult the dealer, or an experienced radio/TV
technician for help. • Designed for 12 or 24 VDC systems

This Class B digital apparatus complies with Canadian PS-MPPT-25M

ICES-003. • Includes metering display
Cet appareil numerique de la classe B est conforme a la • Rated for maximum 25 amps continuous current (battery
norme NMB-003 du Canada. 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

12 General Information ProStar MPPT Operator’s Manual 13

2.4 Features 1 - Charging Status / Error LED
Shows charging current and error condition statuses.
The features of the ProStar MPPT are shown in Figure 2-1
below. An explanation of each feature is provided. 2 - Heatsink
Aluminum heatsink (underneath) to dissipate controller heat (the
ProStar MPPT is 100% passively cooled for reliability)
3 - Meter Display

2.0
Digital LCD monitoring and programming display
8
1 4 - Battery Status / Fault LED Indicators
Three state of charge (SOC) LED indicators show charging status and
2 controller faults
9 5 - Solar Positive and Negative Terminals
3 Power connections for Solar (+) and (-) cable terminations
10 6 - Load Positive and Negative Terminals
4
Power connections for Load (+) and (-) cable terminations
7 - Battery Positive and Negative Terminals
11
Power connections for Battery (+) and (-) cable terminations

12 8 - Local Temperature Sensor

Compensates charging based on ambient temperature (not used if Re-
mote Temperature Sensor is connected)
9 - Meter Directional Buttons
13
5 Used to navigate throughout meter map

14 10 - DIP Switches
6
Eight (8) settings switches to configure operation of the ProStar MPPT
7 15 11 - MeterBusTM Port
RJ-11 socket for Morningstar MeterBusTM network connections
16
12 - Grounding Terminal
Chassis ground terminal for equipment grounding
13 - Battery Sense Terminals
Connection points for battery voltage sensing wires
14 - Remote Temperature Sensor Terminals (RTS)
Figure 2-1. PS-MPPT Features 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

14 General Information ProStar MPPT Operator’s Manual 15

2.5 Optional Accessories Wire Box for ProStar MPPT
A modular wiring box that can be added to any version of
The following accessories are available for purchase ProStar MPPT controller. The box acts as a junction (using
separately from your authorized Morningstar dealer: knock-outs) to run controller wiring to external conduit, if
Remote Temperature Sensor (Model: RTS) desired. The wire box cannot be used with rigid conduit.
The communications accessories / adaptors below should

2.0
The RTS measures battery temperature for accurate
temperature compensation and is recommended when be housed in the Wire Box for ProStar MPPT.
the ambient battery temperature differs from the ambient
controller temperature by more than 5º C. The standard
Communications Support:
cable length is 33 ft (10m). Ethernet MeterBus Converter (EMC-1)
This product is an Ethernet gateway that provides web
NOTE: The use of a Remote Temperature Sensor is monitoring, a Modbus TCP/IP server, and a local web page
strongly recommended. Controller location, air flow, and server. End users can collect information about their off-
system power can drastically affect the local temperature sensor grid PV system remotely by bridging MODBUS TCP/IP
reading. An RTS will provide optimal charging performance. requests to serve LiveView pages, or connect with MSView
RM-1 Meter monitoring software. The EMC-1 supports all products that
have a MeterBus port.
The digital Remote Meter displays system operating
information, error indications, and self-diagnostic read-out. USB Communications Adapter (UMC-1)
Information is displayed on a backlit 4-digit custom LCD A modular unit that uses a USB-B plug, usually from a USB
display. The large numerical display and icons are easy to A-B computer cable, and an RJ-11 plug to connect with a
read and large buttons make navigating the meter menus Morningstar controller's MeterBus port, for monitoring and
easy. Additionally, a status LED and three (3) battery SOC programming using MSView PC software.
LEDs provide system status at a glance.
The meter can be flush mounted in a wall or surface PC MeterBus AdapterTM (Model: MSC)
mounted using the mounting frame (included). The RM-1 is The MSC converts the MeterBus RJ-11 electrical interface
supplied with 33 ft (10.0 m) of cable, a mounting frame, and to an isolated standard RS-232 interface which enables
mounting screws. The RM-1 connects to the RJ- 11 Meter communication between the ProStar MPPT and a personal
port on the ProStar MPPT. computer (PC). The MSC can be used for programming
Ground-fault Protection Device (GFPD-150V) custom charging set-points, and for logging data in MSView.
The GFPD-150V detects power source ground faults See Section 4.7 for more information on programming.
and interrupts current as required by the U.S. National
Electrical Code.

16 General Information ProStar MPPT Operator’s Manual 17

 • Do not install in locations where water can enter the
3.0 INSTALLATION INSTRUCTIONS controller.
• Loose power connections and /or corroded wires
3.1 General Installation Notes may result in resistive connections that melt wire
• Read through the entire installation section first before insulation, burn surrounding materials, or even cause
beginning installation. fire. Ensure tight connections and use cable clamps to
• Be very careful when working with batteries. Wear secure cables and prevent them from swaying in mobile
eye protection. Have fresh water available to wash applications.
and clean any contact with battery acid. • Preset charging profiles are generally designed for
• Use insulated tools and avoid placing metal objects lead acid batteries. Custom settings can be used for

3.0
near the batteries. varied charging requirements (see sections 3.2 and 4.7
for details). Note that some battery types may not be
WARNING: Equipment Damage or Risk of compatible.
Explosion • The ProStar MPPT battery connection may be wired
Never install the ProStar MPPT in an enclosure to one battery, or a bank of batteries. The following
with vented/flooded batteries. Battery fumes instructions refer to a singular battery, but it is implied
are flammable and will corrode and destroy the that the battery connection can be made to either one
ProStar MPPT circuits. battery or a group of batteries in a battery bank.
CAUTION: Equipment Damage • The ProStar MPPT uses stainless steel fasteners,
! When installing the ProStar MPPT in an enclosure, an anodized aluminum heat sink, and conformal
ensure sufficient ventilation. Installation in a coating to protect it from harsh conditions. However,
sealed enclosure will lead to over-heating and a for acceptable service life, extreme temperatures and
marine environments should be avoided.
decreased product lifetime.
• The ProStar MPPT prevents reverse current leakage at
AVERTISSEMENT: Endommagement de night, so a blocking diode is not required in the system.
l’équipement ou risque d’explosion
• The ProStar MPPT is designed to regulate ONLY solar
N’installez jamais le ProStar MPPT dans une (photovoltaic) power. Connection to any other type of
enceinte avec des batteries à évent/à électrolyte power source e.g. wind turbine or generator may void
liquide. Les vapeurs des batteries sont the warranty. However, other power sources can be
inflammables et corroderont et détruiront les connected directly to the battery.
circuits du ProStar MPPT. • With the standard terminal cover, the maximum wire
PRUDENCE: Endommagement de l’équipement size is #6 AWG / 16 mm2 (solid/multi-strand) or #8
! Assurez une ventilation suffisante en cas
d’installation du ProStar MPPT9 dans une enceinte.
AWG / 10 mm2 (fine strand). When using the Wire Box
accessory, the maximum wire size is #2 AWG. Use a
L’installation dans une enceinte hermétique flathead insulated screwdriver, and torque tightly up to
entraîne une surchauffe et une réduction de la 35 in-lb.
durée de vie du produit. • 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

18 Installation Instructions ProStar MPPT Operator’s Manual 19

 conductor free out of the connection screw, and WARNING: Minimum over-current protection
possible contact with the metal enclosure. device interrupt ratings must be 2000A for 12V
• (3) ferrite chokes are included for individual installation systems, and 4000A for 24V systems.
around an RTS cable, a Meterbus cable and a heat-
AVERTISSEMENT: Protection contre les
sink ground wire, if used. Each wire must be looped
surintensités minimum cotes d'interruption de
(at least once) through a ferrite choke, as close to the
périphérique doivent être de 2000 a 12V systèmes et 4000 a pour
ProStar MPPT as possible, to meet FCC Class B EMI
les systèmes de 24V.
requirements.

CAUTION: 3.2 Configuration

!

3.0
For hazardous location-IECEx/ATEX applications,
see the addendum - part no. MS-003244-EN - The DIP switch block shown in Figure 3.1 below is used to
to this manual. set the operating parameters for the ProStar MPPT.
PRUDENCE:
! Pour les applications en environnement dangereux -
IECEx / ATEX, voir l'addendum - référence MS-003244-
FR - à ce Manuel.

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 Figure 3.1. DIP Switch Block to set charging parameters
of 30 amps for the PS-MPPT-25/M and 50 amps for the PS-MPPT-
40/M.
Switch 1: Load / Lighting
AVERTISSEMENT: Solaire et batterie fusibles ou
disjoncteurs DC sont nécessaires dans le système. Ces Mode Switch 1
dispositifs de protection sont externes au contrôleur MPPT Normal OFF
ProStar et doivent être un maximum de 30 ampères pour le Lighting ON
PS-MPPT-25/M et 50 ampères pour le PS-MPPT-40/M.

WARNING: Installation must comply with all Switches 2, 3: System Voltage

US National Electrical Code and Canadian Electrical Three (3) system voltage configurations are available as
Code requirments. Breakers and fuses may require lower ratings shown in the table below:
than referenced above, so as not to exceed any specific wire
ampacity. System Voltage Switch 2 Switch 3
Auto OFF OFF
AVERTISSEMENT: Installation doit être conforme à 12 OFF ON
toutes les requirments US National Electrical Code et
24 ON OFF
Code Canadien d'Electricité. Disjoncteurs et fusibles peuvent
exiger des cotes inférieures que mentionnés ci-dessus de manière
NOTE: Before connecting the battery, measure the open-circuit
à ne pas pour dépasser n'importe quel fils particulier admissible.
voltage. It must be over ten volts to start the controller. If the

20 Installation Instructions ProStar MPPT Operator’s Manual 21

 system voltage Settings Switches are set to Auto-detect, battery Switch 7: Battery Equalization
voltage over 15.5V will be detected as a 24V nominal battery,
and the unit will charge accordingly. The 12/24V auto selection is Mode Switch 7
only done at start-up, and the detected system voltage will never Manual Equalization OFF
change during operation.
Auto Equalization ON
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. Switch 8: Meterbus / MODBUS Settings
Switches 4, 5, 6: Battery Type Selection

3.0
Preset ProStar MPPT battery charging options are shown in Mode Switch 8
table 3-1 below. All voltage settings listed are for nominal Meterbus OFF
12 volt batteries. MODBUS ON
Multiply the voltage settings by two (2) for 24 volt systems.
NOTE: These settings are general guidelines for 3.3 Mounting
use at the operator’s discretion. The ProStar MPPT
can be programmed to satisfy a wide range of charging Inspect the controller for shipping damage. Mount the
parameters. Consult the battery manufacturer for optimal battery ProStar MPPT to a vertical surface (4-#8 stainless steel
charge settings. self-tapping screws are included). Tighten the mounting
screws, using care not to crack the plastic case. Do not
Battery Charging Set-points (@ 25°C): install directly over an easily combustible surface since the
[multiply voltages by (2) for 24 volt systems] heat sink may get hot under certain operating conditions.
DIP For proper air flow, allow at least 15 cm (6 in) of space
Absorp. Float Equalize Absorp. Equalize Equalize Equalize
Switch Battery
Stage Stage Stage Time Time Timeout Interval above and below the controller, and 50 mm (2 in) at the
Settings Type
4-5-6
(volts) (volts) (volts) (mins) (mins) (mins) (days) sides - see Figure 3-2 below. Do not locate in an enclosure
off-off-off 1 - Sealed* 14.00 13.50 150 where battery gases can accumulate.
off-off-on 2 - Sealed* 14.15 13.50 14.40 150 60 120 28

off-on-off 3 - Sealed* 14.30 13.50 14.60 150 60 120 28

NOTE: The heat sink must be in a vertical position (fins
off-on-on 4- AGM/Flooded 14.40 13.50 15.10 180 120 180 28
up and down).
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 15.40 13.40 16.00 180 180 240 14

on-on-on 8 - Custom Custom Custom Custom Custom Custom Custom Custom

* “Sealed” ba�ery type includes gel and AGM ba�eries

Table 3.1. Battery charging settings for each selectable battery type

22 Installation Instructions ProStar MPPT Operator’s Manual 23

 3.4 Wiring

6 in (15 cm)

3.0
SS+-
2 in
(5 cm) 3 2

S+ S- L+ L- B+ B-
4
7 5 6
6 in (15 cm)

To battery (+) and

(-) terminals for
voltage sensing

Figure 3-2. Proper Clearances for Passive Cooling 1 To load (+) To battery (+) To battery for
To properly and (-) and (-) temperature
sized array terminals terminals 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.

24 Installation Instructions ProStar MPPT Operator’s Manual 25

 STEP 1: Check Controller Limitations Generally accepted wiring practice is to limit voltage
Verify that the highest temperature compensated solar array drops between the charger and the battery to 2%. Even
open-circuit voltage (Voc), and load current do not exceed properly sized wiring with 2% drop can result in a 0.3 volt
the ratings of the ProStar MPPT version being installed. drop for 14.4V charging. Voltage drops will cause some
undercharging of the battery.
Multiple controllers can be installed in parallel on the same
battery bank to achieve greater total charging current. The controller will begin Absorption or limit equalization
In this type of system, each ProStar MPPT must have its at a lower battery voltage because the controller measures
own solar array. The load terminals of multiple controllers a higher voltage at the controller’s terminals than is the
can only be wired together if the total load draw does actual battery voltage. For example, if the controller

3.0
not exceed the nameplate current of the LOWEST rated is programmed to start Absorption at 14.4V, when the
controller. controller "sees" 14.4 volts at its battery terminals, the true
battery voltage would only be 14.1 volts, if there is a 0.3 volt
STEP 2: Battery Voltage Sense Wires
drop between the controller and battery.
WARNING: Fire Hazard
When connecting Battery Sense Wires, install a 5 Amp fuse in Note that the battery sense wires will not power the
the (+) sense wire, six inches from the (+) battery terminal. controller, and the sense wires will not compensate for
losses in the power wires between the controller and the
AVERTISSEMENT : Risque d’incendie battery. The battery sense wires are used to improve the
Lors de la connexion des câbles de détection de batterie, accuracy of the battery charging.
installez un fusible de 5 A dans le câble de détection (+), à six
pouces de la borne de la batterie (+). 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
Due to connection and cable resistance, voltage drops are to connect the battery to the voltage sense terminals. A
unavoidable in power cables that carry current, including 2-position terminal (see figure 3.3) is used for the battery
the ProStar MPPT battery cables. If Battery Sense wires are sense connection. A twisted pair cable is recommended but
not used, the controller must use the voltage reading at the not required. Use UL rated 300 Volt conductors. The voltage
battery power terminals for regulation. This voltage may sense wires may be pulled through conduit with the power
differ from the actual battery bank voltage due to voltage conductors.
drop. Observing correct polarity, connect both battery voltage
Battery Voltage Sense is a high impedance connection that sense wires to the ProStar MPPT at the 2-position
enables the ProStar MPPT to measure the battery terminal Battery Sense terminal, and to battery (+) and (-) terminals.
voltage precisely with small gauge wires that have no No damage will occur if the polarity is reversed, but the
voltage drop. When connected directly to the battery, the controller cannot read a reversed sense voltage.
sense wires will improve battery charging accuracy. Battery Tighten the connector screws to 5 in-lb (0.56 Nm) of torque.
voltage sense wires are recommended if the controller is The maximum length allowed for each battery voltage sense
more than three meters (10 ft) from the battery. wire is 98 ft (30 m).

26 Installation Instructions ProStar MPPT Operator’s Manual 27

 Connecting the voltage sense wires to the RTS terminal will Tighten the connector screws to 5 in-lb (0.56 Nm) of torque.
cause an alarm. Separate installation instructions are provided inside the RTS
bag.
NOTE: If the battery input voltage is greater than 5 volts
different than the Battery Sense, due to voltage drops or WARNING: Equipment Damage
faulty connections, the Battery Sense input will not be recognized Never place the temperature sensor inside a battery cell.
by the ProStar MPPT. Both the RTS and the battery will be damaged.
A battery voltage sense connection is not required to AVERTISSEMENT: Endommagement de l’équipement
operate the ProStar MPPT controller, but it is recommended Ne placez jamais la sonde de température dans un
for best performance.

3.0
élément de batterie. Le RTS et la batterie seraient endommagés.
STEP 3: Remote Temperature Sensor CAUTION: The ProStar MPPT will use the local
temperature sensor for compensation if the RTS is not
WARNING: Risk of Fire. used.
If no Remote Temperature Sensor (RTS) is connected,
use the ProStar MPPT within 3m (10 ft) of the batteries. Internal PRUDENCE: Le ProStar MPPT MPPT ne compense pas
Temperature Compensation will be used if the RTS is not la température des paramètres de charges si le RTS
connected. Use of the RTS is strongly recommended. n’est pas utilisé.

AVERTISSEMENT: Risque d'incendie. NOTE: The RTS cable may be shortened if the
Si non Capteur de température distant (RTS) est full length is not needed. Be sure to reinstall the ferrite
connecté, utilisez le MPPT ProStar moins de 3m (10 pi) de les choke on the end of the RTS if a length of cable is removed.
batteries. Compensation de la température interne sera utilisée si This choke ensures compliance with electromagnetic emissions
la RTS n'est pas connecté. Utilisation de la RTS est fortement standards.
recommandé.
REMARQUE: Le câble de RTS peut être raccourci
All charging settings are based on 25°C (77°F). If the si la totalité de la longueur n’est pas nécessaire.
battery temperature varies by 5°C, the charging setting Assurez-vous de réinstaller la bobine en ferrite sur l’extrémité du
will change by 0.15 Volts for a 12 Volt battery. This is a RTS si une longueur de câble est enlevée. Cette bobine assure la
substantial change in the charging of the battery, and the conformité avec les normes d’émissions électromagnétiques.
use of the optional Remote Temperature Sensor (RTS) is
recommended to adjust charging to the actual battery STEP 4: Grounding and Ground Fault Interruption
temperature. The RTS can be added at any time after the
WARNING:
system has been installed. This unit is not provided with a GFDI device. This
Connect the RTS to the 2-position terminal located between charge controller must be used with an external GFDI
the battery (-) and chassis ground terminal lugs (see figure). device as required by the Article 690 of the National
The RTS is supplied with 33 ft (10 m) of 22 AWG (0.34 mm2) Electrical Code for the installation location.
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.

28 Installation Instructions ProStar MPPT Operator’s Manual 29

 NOTE: AVERTISSEMENT : Risque d’incendie
Depending on the country of installation, conductors NE LIEZ PAS le côté négatif du système à la mise à
identified by the color green, or a combination la terre au niveau du contrôleur. Selon les exigences
of green/yellow, shall only be used for earthing par le code local ou les références, le côté négatif du
conductors. système doit être mis à la terre par un GFPD à un seul
point.
AVERTISSEMENT :
L’appareil n’est pas fourni avec un dispositif GFDI. Ce For safety, and effective lightning protection, it is
contrôleur de charge doit être utilisé avec un appareil recommended, and may be required by code, that the
GFDI externe comme requis par le code local ou les negative conductor of the charging system be properly

3.0
références grounded. Do not connect the grounding electrode
Use copper wire to connect the grounding terminal in the conductor (GEC) to the case ground terminal. The ProStar
case, and other dead metal, to earth ground. The grounding MPPT does not have internal ground fault protection; but
terminal is identified by the ground symbol on the case, just where the NEC requires the use of a ground fault protection
above the terminal, as shown below: device (GFPD), the system electrical negative should be
bonded through a GFPD to earth ground at only one point.
The grounding point may be located in the solar, or the
battery circuit. For system grounding electrode conductor
sizing requirements, refer to the NEC Section 690.47, or
applicable local regulations or code.

Figure 3-4. Ground Symbol

STEP 5: Battery Connections - see diagram below
Be sure that DIP switches 2 and 3 are set for 12 or 24V, as
Per NEC 690.45 (A) and NEC Table 250.122, minimum sizes described in Section 3.2
for equipment copper grounding wire are:
NOTE: Before connecting the battery, measure the open-circuit
• ProStar MPPT-25 10 AWG (5 mm2)
voltage. It must be over 10 volts to start the controller. If the
• ProStar MPPT-40 10 AWG (5 mm2) system voltage Settings Switches are set to Auto-detect, battery
Per IEC 62109, minimum sizes for equipment copper 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
grounding wire are:
done at start-up.
• ProStar MPPT-25 7 AWG (10 mm2)
• ProStar MPPT-40 7 AWG (10 mm2) With the battery disconnect open, connect the battery (+)
and (-) wires from the battery to controller. DO NOT CLOSE
OR, of the same, or greater, cross-sectional area as the PV
THE BREAKER AT THIS TIME.
wires.
WARNING: Risk of Fire
DO NOT bond DC system electrical negative to
earth grounding terminal on the controller. Per NEC,
system negative must be bonded to earth ground at
only one point, and through a GFPD if required.

30 Installation Instructions ProStar MPPT Operator’s Manual 31

 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 dis-connnect is a convenient way to break
the PV connection when necessary. DO NOT CLOSE THE
BREAKER AT THIS TIME.

120Voc Maximum

40 Volt 40 Volt 40 Volt

3.0
BATTERY (+) MODULE MODULE MODULE

BATTERY (-)
40 or 55 Amp
Fuse - depending
on model

SOLAR (+)
6 in (150 mm)
MAX.
-
Solar
+ Disconnect
EARTH (- ) (+) (- ) (+) (-) (+)
12V / 24V GROUND
EARTH SOLAR (-)
BATTERY GROUND
STEP 7: Load Connections - see diagram below
CAUTION: Equipment Damage
STEP 6: Solar Connections - see diagram below Do not wire any AC inverter to the load terminals of the
WARNING: Shock Hazard ProStar. Damage to the load control circuit may result. An inverter
The solar PV array can produce open-circuit voltages should be wired to the battery. If there is a possibility that any
in excess of 120 Vdc when in sunlight. Verify that the other load will sometimes exceed the Prostar’s maximum voltage
solar input breaker or disconnect has been opened or current limits, the device should be wired directly to the battery
(disconnected) before installing the system wires. or battery bank. If load control is required, contact Morningstar
Tech Support for assistance.
AVERTISSEMENT: Risque de décharge électrique
Le réseau PV solaire peut produire des tensions de PRUDENCE : Dommages matériels
circuit ouvert supérieures à 120 Vdc à la lumière du Ne pas raccorder n’importe quel convertisseur aux bornes
soleil. Vérifiez que le coupe-circuit ou l’interrupteur de la ProStar. Pourrait endommager le circuit de commande de
d’entrée solaire a été ouvert (déconnexion) avant charge. S’il y a une possibilité que n’importe quelle autre charge
d’installer les câbles du système. dépassera parfois la tension maximale de la Prostar ou limites de
courant, l’appareil doit être câblé directement sur la batterie ou
la batterie. Si le régulateur de charge est nécessaire, contacter le
Support technique de Morningstar d’assistance.

32 Installation Instructions ProStar MPPT Operator’s Manual 33

 Turn the loads off, and connect the load wires to the load If the load does not turn on, it could be for various reasons:
terminals. DO NOT CLOSE THE BREAKER AT THIS TIME.
• the ProStar MPPT is in LVD (red LED on)
• there is a short circuit in the load (LEDs blinking R/G – Y)
• there is an overload condition (LEDs blinking R/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,

3.0
observe that the display is scrolling with proper voltage
40 or 55 Amp and current values. Also, a self- test can be performed with
LOAD (+) Fuse - depending digital meter units.
on model

STEP 9: To Power-down
LOAD (-)
WARNING: Risk of Damage
ONLY disconnect the battery from the ProStar MPPT
AFTER the solar input has been disconnected. Damage to
STEP 8: Power-Up and Verify System Operation the controller may result if the battery is removed while the
ProStar MPPT is charging.
NOTE: Carefully observe the LEDs after each connection.

The LEDs will indicate proper polarity and a good
connection. AVERTISSEMENT: Risque d’endommagement
Le ProStar MPPT MPPT 150V SEULEMENT décon-
Close the battery breaker to power on the controller. Watch necter la batterie APRÈS l’entrée solaire a été déconnectée.
the the charging status, and then the three battery state- Le contrôleur pourrait endommager si la batterie est retirée
of-charge (SOC) LEDs blink in sequence (G-Y-R), confirming quand le ProStar MPPT MPPT 150V est en charge.
proper start-up. If they do not light, check the battery • To prevent damage, power-down must be done in the
polarity (+/–) and battery voltage. reverse order as power-up.
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.

34 Installation Instructions ProStar MPPT Operator’s Manual 35

 High Voltage Strings and Grid-tie Modules
4.0 OPERATION
Another benefit of TrakStar MPPT technology is the ability
to charge 12 or 24 volt batteries with solar arrays of higher
4.1 TrakStarTM MPPT Technology nominal voltages. A 12 volt battery bank can be charged
with a 12, 24, 36 or 48V nominal off-grid solar array. Certain
The ProStar MPPT utilizes Morningstar’s TrakStar Maxi- grid-tie solar modules may also be used as long as the
mum Power Point Tracking technology to extract maximum solar array open circuit voltage (Voc) rating will not exceed
power from the solar module(s). The tracking algorithm the ProStar MPPT 120V maximum input voltage rating at
is fully automatic and does not require user adjustment. worst-case (lowest) module temperature. The solar module
Trakstar technology will track the array maximum power documentation should provide Voc vs. temperature data.
point voltage (Vmp) as it varies with weather conditions, Higher solar input voltage results in lower solar input
ensuring that maximum power is harvested from the array current for a given input power. High voltage solar input
through the course of the day. strings allow for smaller gauge solar wiring. This is especially
Current Boost: helpful for systems with long wiring runs between the solar

4.0
In many cases, TrakStar MPPT technology will “boost” the array and the ProStar MPPT.
solar charge current. For example, a system may have 2
An Advantage Over Traditional Controllers
amps of solar current flowing into the ProStar MPPT and
5 amps of charge current flowing out to the battery. The Traditional controllers connect the solar module directly
ProStar MPPT does not create current! Rest assured that the to the battery when recharging. This requires that the so-
power into the ProStar MPPT is the same as the power out lar module operate in a voltage range that is below the
of the ProStar MPPT. Since power is the product of voltage module’s Vmp. In a 12V system, for example, the battery
and current (Volts x Amps), the following is true*: voltage may range from 10 - 15 Vdc but the module’s Vmp is
typically around 17V. Figure 4.1 shows a typical current vs.
(1) Power Into the ProStar MPPT = Power Out of the ProStar voltage output curve for a nominal 12V off-grid module.
MPPT
(2) Volts In x Amps In = Volts Out x Amps Out 12 Volt Module 12 Volt Module
Current vs. Voltage Output Power
* assuming 100% efficiency i.e. if no losses in wiring and Typical Battery
Voltage Range Maximum
TrackStar
Maximum
Power
Point
conversion existed. Power
Point

CURRENT
Traditional

POWER
Controller
Operating Range

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 VOLTAGE VOLTAGE
10 15 17 10 15 17
maximum power voltage and battery voltage, the greater
the current boost. Current boost can be substantial in Figure 4.1. Nominal 12 volt solar module I-V curve and output power
systems where the solar array is of a higher nominal voltage graph
than the battery as described in the next section.

36 Operation ProStar MPPT Operator’s Manual 37

4.2 Battery Charging The battery must remain in the Absorption charging
stage for a cumulative 150-180 minutes, depending on
4-Stage Charging battery type, before transition to the Float stage will occur.
However, Absorption time will be extended by 30 minutes
The ProStar MPPT has a 4-stage battery charging algorithm if the battery discharges below 12.50 volts (12V system) the
for rapid, efficient, and safe battery charging. Figure 4-2 previous night.
shows the sequence of stages.
The Absorption set-point is temperature compensated
through either the on-board local temperature sensor, or an
optional Remote Temperature Sensor (RTS), if connected.

Float Stage
VOLTAGE

EQUALIZE

After the battery is fully charged in the Absorption stage,

the ProStar MPPT reduces the battery voltage to the Float

4.0
BULK
voltage set-point. When the battery is fully recharged, there
NIGHT ABSORPTION FLOAT NIGHT
CHARGE can be no more chemical reactions and all the charging cur-
rent is turned into heat and gasing. The float stage provides
a very low rate of maintenance charging while reducing the
TIME heating and gasing of a fully charged battery. The purpose
of float is to protect the battery from long-term overcharge.
Figure 4.2. ProStar MPPT Charging Algorithm The green SOC LED will blink once every two (2) seconds
during Float charging.
Bulk Charge Stage
Once in Float stage, loads can continue to draw power from
During Bulk charging, the battery is not at 100% state of the battery. In the event that the system load(s) exceed
charge and battery voltage has not yet charged to the Ab- the solar charge current, the controller will no longer be
sorption voltage set-point. The controller will deliver 100% able to maintain the battery at the Float set-point. Should
of available solar power to recharge the battery. the battery voltage remain below the Float set-point for a
cumulative 60 minute period, the controller will exit Float
Absorption Stage stage and return to Bulk charging.
When the battery has recharged to the Absorption voltage The Float set-point is temperature compensated through
set-point, constant-voltage regulation is used to maintain either the on-board local temperature sensor, or an optional
battery voltage at the Absorption set-point. This prevents Remote Temperature Sensor (RTS), if connected.
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.

38 Operation ProStar MPPT Operator’s Manual 39

Equalization Stage the battery voltage above the standard absorption voltage
so that the electrolyte gases. The green SOC LED will
WARNING: Risk of Explosion blink rapidly two (2) times per second during equalization
Equalizing vented batteries produces explosive gases. charging. The duration of the equalize charge is determined
The battery bank must be properly ventilated. by the selected battery type. See table 4-1 in this section
for more details. The Equalization Time is defined as time
CAUTION: Equipment Damage
! Equalization increases the battery voltage to levels that
may damage sensitive DC loads. Verify all system loads
spent at the equalization set-point. If there is insufficient
charge current to reach the equalization voltage, the EQ
are rated for the temperature compensated Equalize will terminate after an additional 60 minutes to avoid over
voltage before beginning an Equalization charge. gasing or heating of the battery. If the battery requires
more time in equalization, with non-metered versions,
CAUTION: Equipment Damage
! Excessive overcharging and gasing too vigorously can
manual EQ can be activated using the push-button (see
Section 4.5) to continue for one or more additional EQ
damage the battery plates and cause shedding of active
material from the plates. An equalization that is too high cycles. The Prostar MPPT meter, or MSView software, can

4.0
or for too long can be damaging. Review the require- also be used to program EQ timing and duration.
ments for the particular battery being used in your system. The Equalization set-point is temperature compensated
AVERTISSEMENT: Risque d’explosion through either the on-board local temperature sensor, or an
Les batteries à évent et compensation produisent des gaz optional Remote Temperature Sensor (RTS), if connected.
explosifs. Le groupe de batteries doit être correctement
ventilé. Why Equalize?
Routine equalization cycles are often vital to the perfor-
mance and life of a battery - particularly in a solar system.
PRUDENCE: Endommagement de l’équipement
! La compensation augmente la tension des batteries à des
During battery discharge, sulfuric acid is consumed and
soft lead sulfate crystals form on the plates. If the battery
niveaux pouvant endommager les charges sensibles en
CC. Vérifiez que toutes les charges du système sont remains in a partially discharged condition, the soft crystals
conçues pour la tension de compensation par température will turn into hard crystals over time. This process, called
avant de commencer une charge de compensation. “lead sulfation”, causes the crystals to become harder
over time and more difficult to convert back to soft active
PRUDENCE: Endommagement de l’équipement
! Une surcharge excessive et un dégagement gazeux trop
materials. Sulfation from chronic undercharging of the bat-
tery is the leading cause of battery failures in solar systems.
vigoureux peuvent endommager les plaques de batteries
et provoquer l’élimination du matériau actif des plaques. In addition to reducing the battery capacity, sulfate build-up
Une compensation trop élevée ou trop longue peut is the most common cause of buckling plates and cracked
provoquer des dégâts. Examinez les exigences pour la grids. Deep cycle batteries are particularly susceptible to
batterie particulière utilisée dans votre système. lead sulfation.
Normal charging of the battery can convert the sulfate back
Certain battery types benefit from a periodic boost charge to the soft active material if the battery is fully recharged.
to stir the electrolyte, level the cell voltages, and complete However, a solar battery is seldom completely recharged, so
the chemical reactions. Equalization (EQ) charging raises the soft lead sulfate crystals harden over a period of time.
40 Operation ProStar MPPT Operator’s Manual 41
Only a long controlled overcharge, or equalization, at a charging (12V battery). Many VRLA batteries, including
higher voltage can reverse the hardening of sulfate crystals. AGM and gel, have charging requirements up to 14.4V
When to Equalize? (12V battery). Depending on the battery manufacturer’s
recommendation, the “boost” cycle for sealed cells can be
The ideal frequency of equalizations depends on the
disabled by setting the equalize setting switch to manual, if
battery type (lead-calcium, lead-antimony, etc.), the depth
required.
of discharging, battery age, temperature, and other factors.
One very broad guide is to equalize flooded batteries every Battery Charge Settings
1 to 3 months or every 5 to 10 deep discharges. Some
Preset ProStar MPPT battery charging options are shown in
batteries, such as the L-16 group, will need more frequent
tables 4-1 and 4-2 below. All voltage settings listed are for
equalizations.
nominal 12 Volt batteries. Multiply the voltage settings by
The difference between the highest cell and lowest cell in a two (2) for 24 Volt batteries.
battery can also indicate the need for an equalization. Either
the specific gravity or the cell voltage can be measured. NOTE: These settings are general guidelines for
use at the operator’s discretion. The ProStar MPPT

4.0
The battery manufacturer can recommend the specific
gravity or voltage values for your particular battery. can be programmed to satisfy a wide range of charging
parameters. Consult the battery manufacturer for optimal battery
Preparation for Equalization charge settings.
First, confirm that all of the system loads are rated for the
equalization voltage. Consider that at 0°C (32°F) the equal-
ization voltage will reach 16.75 volts for L-16 batteries with Battery Charging Set-points (@ 25°C):
[multiply voltages by (2) for 24 volt systems]
a temperature sensor installed. Disconnect any loads at risk
of damage due to the high input voltage. DIP
Switch Battery
Absorp. Float Equalize Absorp. Equalize Equalize Equalize
Stage Stage Stage Time Time Timeout Interval
If Hydrocaps are used, be sure to remove them before start- Settings
4-5-6
Type
(volts) (volts) (volts) (mins) (mins) (mins) (days)

ing an equalization. Replace the Hydrocaps with standard

off-off-off 1 - Sealed* 14.00 13.50 150
battery cell caps. The Hydrocaps can get very hot during an
off-off-on 2 - Sealed* 14.15 13.50 14.40 150 60 120 28
equalization. Also, if Hydrocaps are used, the equalization
off-on-off 3 - Sealed* 14.30 13.50 14.60 150 60 120 28
should be set for manual only (DIP switch #7 is Off).
off-on-on 4- AGM/Flooded 14.40 13.50 15.10 180 120 180 28
After the equalization is finished, add distilled water to each
on-off-off 5 - Flooded 14.60 13.50 15.30 180 120 180 28
cell to replace gasing losses. Check that the battery plates
on-off-on 6 - Flooded 14.70 13.50 15.40 180 180 240 28
are covered.
on-on-off 7 - L-16 15.40 13.40 16.00 180 180 240 14
Equalize a Sealed Battery? on-on-on 8 - Custom Custom Custom Custom Custom Custom Custom Custom

The Battery Charging Settings table (see table 4-1 in this * “Sealed” ba�ery type includes gel and AGM ba�eries
section) shows two sealed battery settings with an Equaliza-
tion cycles. These are minimal “boost” cycles to level indi-
vidual cells. This is not an equalization, and will not vent gas Table 4.1. Battery charging settings for each selectable battery type
from sealed batteries that require up to 14.4V

42 Operation ProStar MPPT Operator’s Manual 43

 Shared Settings Value Units If battery voltage discharges below 12.50 volts (25.00
Absorption Extension Voltage 12.50 Volts
volts @ 24V) the previous night, Absorption charging will
be extended on the next charge cycle as shown in figure
Absorption Extension Time Absorption Time + 30 minutes
4-3 above. Thirty minutes will be added to the normal
Float Exit Time-out 60 minutes
Absorption duration.
Float Cancel Voltage 12.10 Volts

Equalize Time-out Equalize Time + 60 minutes Float Time-out

millivolts / °C
Temperature Compensation Co-efficient - 30
/ 12V Sub-
Bulk Absorption Float Float Bulk Absorption
Table 4.2. Battery settings that are shared among all battery types

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 Float V

4.0
are suitable for lead-acid batteries ranging from sealed
60 mins.
(gel, AGM, maintenance-free) to Flooded and L-16 cells. below Float

In addition, an eighth charging setting provides for custom

set-points using MSViewTM PC software. Table 4-1 above
time (hrs)
summarizes the major parameters of the standard charging 1:00 2:00 3:00 4:00 5:00 6:00
settings. The shared settings in Table 4-2 are common to
all battery types. The following charging profiles graphically Figure 4-4. Float Exit Time-out Charging Profile
illustrate the shared settings:
Absorption Extension After entering Float stage, the controller will only exit Float
Extended if the battery voltage remains below Float voltage for sixty
Absorption cumulative minutes. In figure 4-4, a system load turns on
Bulk Absorption Float
at 3:30 hrs when the controller is in Float stage, runs for
one hour, and turns off at 4:30 hrs. The load current draw is
larger than the charge current, causing battery voltage to
drop below Float voltage for sixty minutes. After the load
runs for sixty minutes, the time-out causes the controller
to return to Bulk charging, and then Absorption stage
again. In this example, a load runs continuously for sixty
12.50 V Absorption Extension Voltage min. However, because the Float exit timer is cumulative,
multiple momentary load events that pull the battery
time (hrs) voltage below Float voltage for a combined sixty minutes
1:00 2:00 3:00 4:00 5:00 6:00 duration will also force an exit from Float stage.
Figure 4-3. Absorption Extension Charging Profile

44 Operation ProStar MPPT Operator’s Manual 45

Float Cancel Voltage Equalize Time-out

Bulk Absorption Bulk Equalize Float

Equalize V

Absorp. V
Float cancelled this charge cycle

Equalize timeout

12.0 V Float Cancel Voltage

time (hrs)
1:00 2:00 3:00 4:00 5:00 6:00 time (hrs)

4.0
1:00 2:00 3:00 4:00 5:00 6:00
Figure 4.5. Float Cancellation Charging Profile
Figure 4.6. Equalize Time-out Charging Profile

If the battery bank discharges below 12.10 volts (24.20 The charging profile in figure 4-6 above, shows an Equalize
volts @ 24 V) the previous night, Float charging stage will Timeout event. The timeout timer begins as soon as battery
be cancelled for the next charge cycle. Figure 4-5 above, voltage exceeds the Absorption voltage set-point. If there
illustrates this concept. At 0:00 hrs (dawn), battery voltage is insufficient charging current or system loads are too large,
is below the Float Cancel threshold voltage. The diagram the battery voltage may not reach the Equalize set-point.
shows where Float stage would have occurred if Float was Equalize Time-out is a safety feature that prevents high
not canceled. battery voltage for extended periods of time which may
damage the battery.

46 Operation ProStar MPPT Operator’s Manual 47

4.3 Load Control Information LVD Warning:
As the battery discharges, the Battery Status LEDs will
The primary purpose of the load control function is to transition from green to yellow and then from yellow to
disconnect system loads when the battery has discharged to flashing red. The flashing red indication is a warning that a
a low state of charge, and reconnect system loads when the low voltage disconnect (LVD) event will occur soon.
battery is sufficiently recharged. System loads may be lights,
DC appliances, or other electronic devices. The total current
The amount of time between a green SOC indication and
draw of all loads must not exceed the ProStar MPPT 25 or
load disconnect will depend on many factors including:
30 Amp maximum load rating.
• rate of discharge (amount of load draw)
CAUTION: Equipment Damage • capacity of the battery
Do not wire any AC inverter to the load terminals of the
ProStar. Damage to the load control circuit may result. • health of the battery
An inverter should be wired to the battery. If there is a possibility • LVD set-point
that any other load will sometimes exceed the Prostar’s maximum
voltage or current limits, the device should be wired directly to the

4.0
battery or battery bank. If load control is required, contact Morn- If the battery discharges to the LVD set-point the load will
ingstar Tech Support for assistance. disconnect and a solid red Battery Status LED indication will
be displayed.
PRUDENCE : Dommages matériels
Ne pas raccorder n’importe quel convertisseur aux bornes General Load Control Notes:
de la ProStar. Pourrait endommager le circuit de commande de
charge. S’il y a une possibilité que n’importe quelle autre charge Do not wire multiple ProStar MPPT load outputs together in
dépassera parfois la tension maximale de la Prostar ou limites de parallel to power DC loads with a current draw greater than
courant, l’appareil doit être câblé directement sur la batterie ou 25 or 30A, depending on the ProStar MPPT model in use.
la batterie. Si le régulateur de charge est nécessaire, contacter le Equal current sharing cannot be assured and an over-load
Support technique de Morningstar d’assistance. condition will likely occur on one or more controllers.
Current Compensation: Exercise caution when connecting loads with specific
All LVD and LVR set-points are current compensated. polarity to a live load circuit. A reverse polarity connection
Under load, the battery voltage will sag in proportion to the may damage the load. Always double check load
current draw of the load. A short-term large load could connections before applying power.
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

48 Operation ProStar MPPT Operator’s Manual 49

4.4 LED Indications NOTES:
1) R flashing is generally a user addressable fault / error
KEY:
G = green G - Y - R = flashing sequencially 2) R charging status LED ON with heartbeat blink OFF
every 5 secs is a critical fault that generally requires service.
Y = yellow G/Y = flashing together
See, "Solid Charging Status LED with Self-test (R-Y-G) SOC
R = red G / Y - R = G and Y flashing together,
Faults", in Section 5.1.
alternating with R flash
4.4.1. Power-up 4.4.3 State-of-Charge LEDs
Normal power-up: Status LED flashes G, then SOC LEDS Battery SOC LED Indications are shown in Table 4-5 below:
flash G - Y - R, sequentially, then SOC LEDs will indicate
battery charge status with one or two lit battery status LEDs. Condition Indication
Failed bootload: Status LED flashes G, then SOC LEDS Absorption G flash - every sec
flash G - Y and stop on solid Y. Float G flash - every 2 secs

4.0
4.4.2 Status LED Start EQ (push-button) [G / Y / R] x2 - G- G
Stop EQ (push-button) [G / Y / R] x2 - R - R
The Status LED indicates charging status and any exist-
ing solar input error conditions. The Status LED is on when Equalize G flash - 2 / sec
charging during the day and off at night. The Status LED will SOC > 13.5V G solid
flash red whenever an error condition(s) exists. Table 4.4 lists 13.5V > SOC > 13.0V G / Y solid
the Status LED indications. 13.0V > SOC > 12.5V Y solid
SOC < 12.5V Y / R solid
Operating Low voltage disconnect
Color Indication R flash - every sec
State warning
Off (with heart- Low voltage disconnect R solid
None Night
beat¹) Table 4.5. Battery SOC LED Indications
On Solid
Green (with heart- Charging 4.5 Push-Button Use in Non-Metered Version
beat²) The version of the ProStar MPPT without meter display
Red Flashing Error features a push-button that operates as follows depending
On Solid on the DIP Switch 1 setting:
Red (with heart- Critical Error Normal Mode (DIP 1 OFF)
beat2)
• Regardless of the DIP 7 setting, press and hold the push-
¹ heartbeat indication flickers the Status LED on briefly every 5 seconds button for 5 seconds to initiate or stop an Equalization
² heartbeat indication flickers the Status LED off briefly every 5 seconds (EQ).

Table 4.4. Status LED Definitions

50 Operation ProStar MPPT Operator’s Manual 51

Lighting Control Mode (DIP 1 ON) temperatures lower than specified in the graphs indicate
A quick press of the push-button will conduct a ten minute insufficient airflow. Maximum charging current depends
lighting test. A lighting test is used to verify correct wiring in on many factors, and good ventilation can greatly reduce
the load circuit and /or verify that the lighting components the amount of de-rating. If the controller frequently reports
are operational. The lighting test will override LVD for ten this alarm condition, corrective action should be taken to
minutes - the override duration is not programmable. provide better air flow, or to move the controller to a cooler
location.
• Press and hold the push-button for five seconds to initiate
or stop an Equalization (EQ). High Input Voltage Current Limit
The ProStar MPPT will limit the solar input current as the
Reset PS-MPPT to Factory Settings
solar array Voc approaches the maximum input voltge
To restore factory settings: Disconnect PV; disconnect rating. The array Voc should never exceed the 120 volt
battery power; press and hold down the push-button; maximum input voltage - see the array voltage de-rating
re-start the PS-MPPT by connecting the battery; keep the graph in Appendix.
push-button depressed for 3-5 secs, until the battery LEDs

4.0
Current Limit
start to cycle R-Y-G. The array power exceeds the rating of the controller. This
A Custom Edit Settings fault will occur. See Section 5 for alarm indicates that the ProStar MPPT is limiting battery
details. The unit will need to be re-powered to resume current to the maximum current rating.
normal operation. RTS Open
4.6 Alarms The Remote Temperature Sensor is not connected to the
controller. Use of the RTS is recommended for proper
Solar Overload battery charging.
No LED indication. The ProStar MPPT will limit battery Heatsink Temperature Sensor Open / Shorted
current to the 25 or 40 amp maximum rating. An over-sized The heatsink temperature sensor is damaged. Return the
solar array will not operate at peak power. The solar array controller to an authorized Morningstar dealer for service.
should be less than the ProStar MPPT nominal max. input
power rating for optimal performance. See Section 7.0 - Battery Sense Out of Range / Disconnected (only alarm
Technical Specifications for more information. with LED indications)
Error status LED: Flashing red. Battery status LEDs: R/Y
High Temperature Current Limit - G/Y sequencing. A battery sense wire is disconnected.
The ProStar MPPT will limit the solar input current if the Inspect the battery sense connections. This alarm is set
heatsink temperature exceeds safe limits. Solar charge when the voltage at the battery sense terminals differs
current will be tapered back (to 0 amps if needed) to by more than five volts from the voltage at the battery
reduce the heatsink temperature. The Appendix B de-rating terminals.
graphs indicate maximum ambient temperatures at which
Uncalibrated
the ProStar MPPT will operate with full-rated current; as
indicated in each graph, maximum ambient temperature The controller was not factory calibrated. Return the
controller to an authorized Morningstar dealer for service.
depends on array input voltage. Actual de-rating
52 Operation ProStar MPPT Operator’s Manual 53
4.7 Custom Settings 4.7.2 Programming in MSView
Beyond the preset DIP switch options, the Prostar MPPT's
4.7.1 Programming with the Meter Display charging profile and all other settings are customizable
The ProStar MPPT is available in metered and non-metered using MSView PC software available at:
versions. The metered model allows: www.morningstarcorp.com
• Custom programming, including lighting programs and
WARNING: Risk Of Electrical Shock.
low battery temperature foldback, directly from the unit.
Hazardous voltage is present at the Meterbus
• Extensive settings adjustment and information as shown
communications port. Use 150V rated, 4 or 6 conductor UL
partially in Figure 4-7 below:
listed telephone cable.
Models: Display Screens and Programming
PS-MPPT-25M
PS- MPPT- 40M AVERTISSEMENT: Risque de choc électrique.
Tension dangereuse est présente dans le port de
communication de transfert. Utilisez 150V évalué, 4 ou 6

4.0
conducteurs câble de téléphone répertorié UL.
Main Screens Solar Current - Battery
Daily Charging Stage - Time
Daily Charge Transferred - Daily Max / Min
Current - Load Current Battery and Load Battery Voltages
With a connection to a PC, and to the RJ-11 port of the PS-
COMMANDS Clear Resettable Ah MPPT, the MSView ProStar MPPT Set-up Wizard is capable
STATUS Faults
Clear Total Ah

Clear KWh
of editing all charging and lighting parameters, for upload
Alarms
Charge State
Load / Light State Load Disconnect to the controller. The Set-up Wizard, and topics within the
HISTORY
See Complete History
Screens Online, or in
Error Log
Target Voltage
Battery Temp.
Battery Sense
Start Lighting Test Help tab describe programming procedures in detail.
Manual Insert Input Voltage Factory Reset
Last Equalization
Graphs

SYSTEM
Serial No.
Hour Meter
Reset Control
All aspects of connection, programming and
communications are covered in the Product Connectivity
Firmware Version
Battery Type Records
Absorption Voltage
Float Voltage
CUSTOM PROGRAMMING:
See Complete
To
Programming
EQ Voltage
Input Mode
Manual:
Programming Screens System Voltage
Online or in Manual Insert
Screens
www.morningstarcorp.com
DISPLAY
SETTINGS Communications accessories / adapters are housed in the
See Complete
Programming Screens
Online or in Manual Insert
Backlight
Backlight Timer
optional Wire Box for ProStar MPPT.
Contrast
Brightness 4.7.3 Meter Display Operation
Auto Scroll

Auto Scroll Timer 4.7.3.1 Directional Key Use and Operation / Navigating
Auto Return
the Meter Map
Temp. Units

Language The ProStar MPPT's meter map consists of two main axes:
Figure 4-7. Simplified Meter Map. For metered models, see The horizontal top level daily monitoring screens, and
the included complete meter map insert, also available in the the vertical Main Menu stacked screens. The four lighted
ProStar MPPT support documents at: triangular directional control keys allow movement to reach
www.morningstarcorp.com any desired point on the meter map. A lit key indicates

54 Operation ProStar MPPT Operator’s Manual 55

a valid direction in the map. The current location is With DIP 1 OFF (down), all lighting control functions are
indicated on the display with a column heading, and a bold disabled.
descriptor. Using either MSView or the meter display, four channels
4.7.3.2 Adjusting the Meter Display are available for setting timers that can work separately, or
in combination. See Section 4.7.6 - Lighting Programming
The display setting options, as shown in Figure 4-7, are Using Meter Display - for more details.
adjustable by using the directional keys to locate and edit a
desired setting or variable. 4.7.6 Lighting Programming Using the Meter Display
Lighting programming capabilities are accessible with the
4.7.4 Using the Meter Display to Program Charging meter via Custom Programming->Load Control->Lighting.
Set-points, Load Control, Communications, and Advanced Lighting settings editing is done via on-screen instructions.
Settings
• The Summary provides a graphical representation of the
Refer to the complete meter map insert for metered PS- complete lighting configuration
MPPTs. From a top level monitoring screens, scroll down to • LVD / LVR can be specified for use when a lighting
the Main Menu - "Custom Programming" - screen. Select

4.0
program is in operation
the desired category, and edit the variable or settings • Sunrise and Sunset Threshold settings allow the
as instructed in the meter display. Note that charging adjustment of percentages of the maximum seen solar
set-points should be entered as if for a 12V system - DIP array voltage for triggering day and night events
switches 2 and 3 settings prompt the controller to multiply • There are four channels, each having two timers, which
if necessary. TIP: Using the meter, Float and EQ stages can can be used independently, or in combination.
be disabled by setting these voltages to 0V. • Events and actions are used as references and controls.
The Load Control category includes Normal (load An event is one of eight points in a day e.g. sunrise or
disconnect) and Lighting programming. The Advanced midnight. Each event can be edited to specify a time
Settings category includes more optional charging, MPPT, offset to trigger an action, which can be, "Do Nothing",
and load control settings. "Lights On", or "Lights Off"
NOTE: Without DIPs 4,5,6 ON (up), only COM address • The combination setting of each channel will specify
settings options will appear in the meter map. To view and whether the actions and events of each timer will function:
not at all (no combination); when both timers' settings
program custom settings via the meter display, DIPs 4,5,6
match (AND); for either timers' settings (OR)
must be in the ON (up) position.
4.7.5 Lighting Control / Programming Overview 4.7.7 Low Temperature Foldback
The ProStar MPPT has a Low Temperature Foldback option
The ProStar MPPT display has extensive lighting load
which can be used to protect lithium batteries from being
programmability.
charged in cold conditions. Custom settings defining the
With DIP switch 1 ON (up), a dusk-dawn lighting program is bounds of charge current reduction due to low battery
enabled, if lighting timing hasn't been programmed in MS- temperature can be programming in MSView, or with
View or using the meter; with DIP 1, 4, 5, 6 ON, and the unit the Advanced Custom Settings options with the display
programmed, custom timing will be in effect. interface.

56 Operation ProStar MPPT Operator’s Manual 57

Advanced Custom Settings options are available with
Schedule Maintenance Items
ProStar MPPT built-in meter models (PS-MPPT-25M and
PS-MPPT-40M).
Re-tighten power terminal
The High Limit defines the lowest temperature at which the 2 weeks after installation connections to specified
controller will deliver 100% of the controller’s rated output torque values.
charging current. The Low Limit defines the temperature
at which the controller will stop providing battery charging
current. The charge current is tapered linearly from the High Re-tighten power terminal
3 months after installation connections to specified
Limit to the Low Limit. torque values.
NOTE: Local meter display setup required for Low Limit <
1° Celsius. Inspect the battery bank.
Look for cracked or
4.8 Inspection and Maintenance bulging cases, and corroded
terminals.

4.0
Table 4-6 below lists the recommended maintenance For wet cell (flooded type)
schedule to keep your ProStar MPPT performing optimally. Monthly or After Each batteries, make sure the
Equalization water level is correct. Wet
WARNING: Risk Of Electrical Shock. cell water levels should be
No power or accessory terminals are electrically checked monthly or
isolated from dc input, and may be energized with hazardous according to the
solar voltage. Under certain fault conditions, battery could manufacturer’s
become over-charged. Test between all terminals and ground recommendations.
before touching.
AVERTISSEMENT: Risque De Choc Életrique. Clean the heatsink fins with a
Non alimentation ou aux bornes d'accessoires sont clean, dry rag.
isolés électriquement de l'entrée de c.C et doit être alimentés Inspect all wiring for
à une tension dangereuse solaire. Sous certaines conditions de damage or fraying.
défaillance, la batterie pourrait devenir trop chargée. Test entre
toutes les bornes et la masse avant de toucher. Inspect for nesting insects.
WARNING: Shock Hazard Annually Re-tighten all wiring terminal
Disconnect all power sources to the controller before connections to specified
removing the wiring box cover. Never remove the cover when torque values.
voltage exists on the ProStar MPPT power connections. Inspect the system earth
grounding for all compo-
AVERTISSEMENT: Risque de décharge électrique nents. Verify all grounding
Déconnecter toutes les sources d'alimentation pour le conductors are appropriately
contrôleur avant d'enlever le couvercle de boîte de connexion. secured to earth ground.
N'enlevez jamais le couvercle lorsque tension existe sur les
connexions d'alimentation ProStar MPPT.
Table 4-6. Maintenance Schedule

58 Operation ProStar MPPT Operator’s Manual 59

 5.0 TROUBLESHOOTING 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
WARNING: RISK OF ELECTRICAL SHOCK. seconds apart. If the overload remains after two (2)
NO POWER OR ACCESSORY TERMINALS ARE ELEC- attempts, the load will remain disconnected until power is
TRICALLY ISOLATED FROM DC INPUT, AND MAY BE ENER- removed and re-applied.
GIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN
FAULT CONDITIONS, BATTERY COULD BECOME OVER- Solar Short Circuit
CHARGED. TEST BETWEEN ALL TERMINALS AND GROUND Charging Status LED: OFF. Solar input power wires are
BEFORE TOUCHING. short-circuited. Charging automatically resumes when the
short is cleared.
AVERTISSEMENT: RISQUE DE CHOC ÉLECTRIQUE. Battery Reverse Polarity
NON ALIMENTATION OU AUX BORNES No LED indication, the unit is not powered. No damage to
D'ACCESSOIRES SONT ISOLÉS ÉLECTRIQUEMENT DE the controller will result. Correct the miswire to resume
L'ENTRÉE DE C.C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION
normal operation.
DANGEREUSE SOLAIRE. SOUS CERTAINES CONDITIONS DE
DÉFAILLANCE, LA BATTERIE POURRAIT DEVENIR TROP CHAR- Load Short Circuit
GÉE. TEST ENTRE TOUTES LES BORNES ET LA MASSE AVANT Error status LED: Flashing red. Battery status LEDs: R/G-Y
DE TOUCHER. sequencing. Fully protected against load wiring short-
circuits. After two (2) automatic load reconnect attempts (10
WARNING: Shock Hazard seconds between each attempt) the ProStar MPPT will wait,

5.0
A means of disconnecting all power supply poles must and then automatically reconnect the load, once the short is
be provided. These disconnects must be incorporated cleared.
in the fixed wiring. Open all power source disconnects before
High Solar Voltage Disconnect
removing controller wiring cover, or accessing wiring.
Charging Status LED: R flashing. No battery status errors.
AVERTISSEMENT: Risque de décharge électrique If the solar input open-circuit voltage (Voc) exceeds the 120
Un moyen de déconnexion de tous les poteaux Volt maximum rating, the array will remain disconnected
d'alimentation doit être fourni. Ceux-ci se déconnecte doit until the Voc falls safely below the maximum rating.
être intégrée dans le câblage fixe. Ouvrir que toutes les source
d'énergie se déconnecte avant de retirer le couvercle de la Remote Temperature Sensor (RTS)
contrôleur, ou accès au câblage. 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
5.1 LED Fault Indications charging. Charging automatically resumes when the
Load Over-current problem is fixed. To resume operation without an RTS,
Error Status LED: Flashing red. Battery status LEDs: R/Y- disconnect all power to the ProStar MPPT and then
G sequencing. If the load current exceeds the maximum reconnect. If the controller is re-started with the failure
load current rating, the ProStar MPPT will disconnect the still present, the controller may not detect that the RTS is
load. The greater the overload the faster the load will be connected, and the LEDs will not indicate a fault.

60 Troubleshooting ProStar MPPT Operator’s Manual 61

A metered model, an RM-1 meter, or MSView PC software, than the controller can regulate, and it shuts off to protect
can be used to determine if the RTS is working properly. the circuitry. The controller will automatically re-start in 10
seconds.
Solar-Battery High Voltage Disconnect (HVD)
Settings (DIP) Switch Changed
Error status LED: Flashing red. Battery status LEDs: R-G
Error status LED: Flashing red. Battery status LEDs:
sequencing. This fault is set when battery voltage is above
R-Y-G sequencing. If a settings switch is changed while
normal operating limits. The controller will disconnect the
there is power to the controller, the LEDs will begin
solar input and set a Solar High Voltage Disconnect fault.
sequencing and the solar input will disconnect. The
This fault is commonly caused by other charging sources in
the system, charging the battery above the ProStar MPPT controller must be re-started to clear the fault and begin
regulation voltage. Recovery occurs at HVD re-connect operation with the new settings.
threshold, and the fault will clear automatically. Custom Settings Edit
Error status LED: Flashing red. Battery status LEDs: R-Y-G
Load High Voltage disconnect (HVD) - disabled by default sequencing. A value has been modified in custom settings
Error status LED: None. Battery status LEDs: R-G memory. The controller will stop charging and indicate a
sequencing. This fault is set when battery voltage is above fault condition. After all settings have been modified, the
normal operating limits. The controller will disconnect controller must be reset by removing and then restoring
the load output and set a Load High Voltage Disconnect power to the controller. The new programmed settings will
fault. This fault is designed to protect sensitive loads be used after the power reset.
from excessive voltage. Recovery occurs at HVD re-
Firmware Update Failure

5.0
connect threshold, if programmed, and the fault will clear
automatically. The firmware update was not successfully programmed. The
controller will not indicate the full power-up LED sequence
High Heatsink Temperature of G-Y-R when power to the controller is reset. Instead, the
Error status LED: Flashing red. Battery status LEDs: R-Y controller will display green, and then stop on yellow. The
sequencing. The heatsink temperature has exceeded safe yellow LED will continue to be lit and the controller will not
limits and the load is disconnected. The load will automati- complete start up or begin charging.
cally reconnect when the heatsink cools to a safe
Re-try the firmware update. The firmware must be
temperature.
successfully loaded before the controller will start up.
Battery Over-current
Error status LED: Flashing red. Battery status LEDs:
R/Y-G sequencing. While rare, if battery 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

62 Troubleshooting ProStar MPPT Operator’s Manual 63

 5.2 Battery Charging and Performance Issues
SOLID CHARGING STATUS LED with SELF-TEST (R-Y-G) Problem:
SOC FAULTS No LED indications, controller does not appear to be
Verify that nothing has been mis-wired. If not, the error is powered
likely critical. Contact an authorized Morningstar dealer for Solution:
support. With a multi-meter, check the voltage at the battery
Fault Charging Status LED Battery SOC LEDs terminals on the ProStar MPPT. Battery voltage must be 10
vdc or greater. If the voltage on the battery terminals of the
PV FET Short Solid red R-Y-G sequencing controller is between 10 and 35 vdc, and no LEDs are lit,
contact your authorized Morningstar dealer for service.
Load FET Short Solid red R-Y-G sequencing If no voltage is measured, check wiring connections, fuses,
and breakers.
Load FET Open Solid red R-Y-G sequencing
Problem:
Damaged local Solid red (only if RTS The ProStar MPPT is not charging the battery.
temperature sensor R-Y-G sequencing
is invalid)
Damaged heatsink Solution:
temperature sensor Solid red R-Y-G sequencing
Check the three (3) battery SOC LEDs. If they are flashing in
Software Solid red R-Y-G sequencing a sequence, see Section 4.5 LED indications of this manual
to determine the cause. A metered model, an RM-1 meter,

5.0
or MSView PC software will display active faults and alarms.
RE-SETTABLE SELF-TEST (R-Y-G) SOC FAULTS
If the LED indications are normal, check the fuses,
Fault - Battery SOC LEDs
breakers, and wiring connections in the power source wir-
Custom Settings Edit - R-Y-G sequencing ing. With a multi-meter, check the array voltage directly at
DIP Switch Change - R-Y-G sequencing 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 ProStar MPPT Operator’s Manual 65

 • Damage resulting from acts of nature such as lightning and weather
6.0 WARRANTY & POLICIES
extremes, or infestation
WARRANTY THE WARRANTY AND REMEDIES SET FORTH ABOVE ARE
LIMITED WARRANTY - Morningstar Solar Controllers and Inverters EXCLUSIVE AND IN LIEU OF ALL OTHERS, EXPRESS OR IMPLIED.
MORNINGSTAR SPECIFICALLY DISCLAIMS ANY AND ALL IMPLIED
All Morningstar Professional SeriesTM products, except the SureSineTM WARRANTIES, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF
inverter, are warrantied to be free from defects in materials and MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. No
workmanship for a period of FIVE (5) years from the date of shipment Morningstar distributor, agent or employee is authorized to make any
to the original end user. Warranty on replaced units, or field-replaced modification or extension to this warranty.
components, will be limited only to the duration of the original product
MORNINGSTAR IS NOT RESPONSIBLE FOR INCIDENTAL OR
coverage.
CONSEQUENTIAL DAMAGES OF ANY KIND, INCLUDING BUT NOT
Morningstar Essentials SeriesTM, and SureSineTM inverter, products are LIMITED TO LOST PROFITS, DOWNTIME, GOODWILL OR DAMAGE
warrantied to be free from defects in materials and workmanship for a TO EQUIPMENT OR PROPERTY.
period of TWO (2) years from the date of shipment to the original end

user. Warranty on replaced units, or field-replaced components, will be

limited only to the duration of the original product coverage.
Morningstar will, at its option, repair or replace any such defective units. MORNINGSTAR TECHNICAL SUPPORT POLICIES

CLAIM PROCEDURE:
Morningstar’s Technical Support Group is dedicated to
Before requesting warranty service, check the Operator’s Manual to providing unparalleled customer support.
verify product failure. Return the defective product to your authorized
Morningstar distributor with shipping charges prepaid. Provide proof of MS Support Scope:
date and place of purchase.
An RMA number must be issued by Morningstar prior to return 1. Determining correct or failed functionality of a
of any unit(s) under this warranty. RMA information must include Morningstar product or system of Morningstar devices. It is

6.0
product model, serial number, detailed failure description, panel expected that owners/operators will use manuals (including
type, array size-configuration, type of batteries and system load troubleshooting sections) before requesting technical
details. This information is critical to rapid disposition of your support.
warranty claim.
Morningstar will pay the return shipping charges if the repairs are cov- 2. Providing product warranty replacements in accordance
ered under the warranty. with the terms of Morningstar’s warranty policy.
WARRANTY EXCLUSIONS AND LIMITATIONS
3. Assisting with the operability of all product / system
This warranty does not apply under the following conditions:
features and functions described in Morningstar manuals
• Damage by accident, negligence, abuse or improper use
and datasheets.
• PV or load currents exceeding the ratings of the product
• Unauthorized product modification or attempted repair
• Damage occurring during shipment

66 Warranty and Policies ProStar MPPT Operator’s Manual 67

Please be advised: WARRANTY CLAIM PROCEDURE

♦ The Morningstar Technical Support Group generally 1. Before proceeding, please refer to product manual,
provides referrals for requested system consultations or including Troubleshooting section.
design/configuration/sizing services. Distributors, dealers, 2. Contacting your authorized Morningstar distributor or
system designers, installers and vast online resources - dealer from whom you purchased the unit is the first step
including the String Calculator array design tool (at www. in the warranty process. Local dealers can often address
morningstarcorp.com) - are available to assist in these areas. warranty issues quickly.
Morningstar can help refer customers to a nearby authorized
distributor, dealer, or installer if assistance is required in 3. If supplier is unable to address the issue, please contact
designing a renewable energy system that best suits your Morningstar by e-mail ([email protected]) with:
specific needs. (A) purchase location - business or company name - and
date
♦ Please visit the Tech Support section at
www.morningstarcorp.com for any documentation or (B) full model and serial numbers (SN is 8-digits on unit
specification needs before requesting support. The site bar label)
also offers an array sizing tool (String Selector), product (C) failure behavior, including LED indications
comparison tool (Product Comparator) and articles on solar
(D) array configuration, panel Pmax, Voc, Vmp, Isc, and
charging technologies and other design considerations.
nominal battery voltage; these specifications are
needed to receive assistance.
♦ Although emergencies do arise when a phone call is
(E) multi-meter available (for field troubleshooting)
necessary, e-mail is the best way to contact us, and will
result in the quickest response. Please use the support 4. After warranty replacement has been approved and new
request form Contact Us (preferred), or e-mail us directly at unit(s) received, please return failed unit(s) using pre-paid
[email protected] shipping label, and follow any product specific instructions if

6.0
requested by Morningstar Warranty Dept.
5. If instructed by Morningstar, after warranty replacement
Thank you for your business, and we look forward to
shipment has been received, return of failed unit(s) is
assisting you.
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 ProStar MPPT Operator’s Manual 69

 Battery Charging Set-points (@ 25°C):
7.0 TECHNICAL SPECIFICATIONS
[multiply voltages by (2) for 24 volt systems]
PS-MPPT-25 PS-MPPT-40 DIP
Absorp. Float Equalize Absorp. Equalize Equalize Equalize
PS-MPPT-25M PS-MPPT-40M Switch Battery
Stage Stage Stage Time Time Timeout Interval
Settings Type
Electrical: 4-5-6
(volts) (volts) (volts) (mins) (mins) (mins) (days)

Nominal Battery Voltage All: 12 or 24 Volts off-off-off 1 - Sealed* 14.00 13.50 150
Battery Voltage Range All: 10-35 Volts off-off-on 2 - Sealed* 14.15 13.50 14.40 150 60 120 28
Voltage Accuracy All: 0.1% +/- 50mV off-on-off 3 - Sealed* 14.30 13.50 14.60 150 60 120 28
Max. Battery Current 25 Amps 40 Amps off-on-on 4- AGM/Flooded 14.40 13.50 15.10 180 120 180 28
Max. PV Open-Circuit Voltage All: 120 Volts
on-off-off 5 - Flooded 14.60 13.50 15.30 180 120 180 28
Load Current Rating 25 Amps 30 Amps
on-off-on 6 - Flooded 14.70 13.50 15.40 180 180 240 28
Self-Consumption All: ~0.6W (no meter) ~1.0W (w/backlit meter)
on-on-off 7 - L-16 15.40 13.40 16.00 180 180 240 14
LED Indications (1) status, (3) battery SOC
on-on-on 8 - Custom Custom Custom Custom Custom Custom Custom Custom
Transient Surge Protection 4500 watts (solar, battery, load)
Conversion Efficiency (peak) All: 97.3% * “Sealed” ba�ery type includes gel and AGM ba�eries

Mechanical: Current Compensation:

Dimensions: 12 volt systems -15 mV / A
Standard 7.87(W) x 7.62(L) x 2.76(D) in. / 24 volt systems -30 mV / A
20.0(W) x 19.4(L) x 7.0(D) cm Compensated set-points LVD
Compensation threshold 3A
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 Load and Solar Control (multiply voltages by (2) for 24 volt
Weight: systems):
Standard Version 3.1 lb /1.4 kg Default values (customizable)
Standard Version with Wire Box 3.4 lb /1.5 kg LVD1 11.5V
Wire Size Range: LVR
1
12.6V
Power Terminals 2.5 - 16 mm2 / #14 - 6 AWG (up to #2 AWG Instant LVD 10.0V
with Wire Box)
HVD - solar Highest set-point in
Maximum torque 35 in-lb
preset charging profile
Battery voltage sense and RTS 0.25 - 1.0 mm2 / #24 - 16 AWG [+ 0.5V (@ 25ºC)]
Maximum torque 5 in-lb
HVD - load1 Disabled
Knock-outs (Wire Box option only) M20, 1/2", 1" (trade sizes)

7.0
HVDR - solar 13.8V (@ 25ºC)
Enclosure IP20, Type 1
HVDR - load1 Disabled
Battery Charging: LVD Warning 4 minutes
4-Stage Charging: Bulk, Absorption, Float, Equalize LVD Override - Lighting Test 10 minutes
Temperature compensation Maximum # LVD overrides No limit unless
Coefficient: -30mV / 12 volt / ºC (not customizable) V_batt < Instant LVD
Temperature compensated
set-points: Absorption, Float, Equalize, HVD 1
Applies to units with Firmware v27 and higher
and HVDR (solar)

70 Technical Specifications ProStar MPPT Operator’s Manual 71

Lighting Control (DIP 1 ON):
APPENDIX A - Efficiency Graphs
Lighting Timer Setting Dusk-Dawn (default)
Lighting Test Timer 10 minutes

600
Data & Communications:
Communication Port MeterBus
Comm. Protocols Morningstar MeterBus;

550
31 Vmp
62 Vmp
93 Vmp
MODBUS
Datalogging 6-8 months, daily records

500
PC Software MSView
Digital Meter:
Resolution 128 x 64

450
Viewing Area 70mm x 40mm
Display Color blue on white

ProStar MPPT Efficiency 12 Volt System

400
Backlight LED
Operating Temperature -20ºC to +60ºC
Storage Temperature -30ºC to +80ºC

350
Output Power (Watts)
Environmental:
Maximum Operating Altitude 2000 meters
Ambient Temperature Range:

300
T4 Certified -40°C to +60°C
T5 Certified -40°C to +45°C
Storage Temperature -40ºC to +80ºC

250
Humidity 100% n.c.
Tropicalization Conformally coated PCBs;

200
Marine-rated terminals
For hazardous location-IECEx/ATEX applications, see the
addendum - part no. MS-003244-EN - to this manual.

150
Protections
Power-up against any active faults

100
Reverse Polarity - battery and array
Solar Short-Circuit
High Solar Voltage Disconnect

50
High Heatsink Temperature - Current De-rating
High Heatsink Temperature - Load Disconnect

0
Load Short-Circuit
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
Load Over-Current
Heatsink Temperature Limit Efficiency (%)
RTS Terminals
Battery Sense Terminals
72 ProStar MPPT Operator’s Manual 73
Technical Specifications
 APPENDIX B - De-rating Graphs

950 1000 1050 1100 1150

Battery Current vs. Array Voltage
PS-MPPT 40A Charging Current vs. Array Voltage
62 Vmp
93 Vmp

O V E R - V O L T A G E
40

900
Charging

850
Current
(Amps)

800
ProStar MPPT Efficiency 24 Volt System

R A N G E !
750
700
Output Power (Watts)
0

650
80 85 90 95 100 105 110 115 120

600
Array Voltage (Volts)

550
Battery Current vs. Array Voltage

500
PS-MPPT 40 (mounted vertically on wall)
450
Charging Current vs. Ambient Temp.
400

45
350

40 PS-40
31 VMP
300

35 12 & 24V
Max. PS-40
250

30
Charging 62 VMP
Current 25 12 & 24V
200

(Amps) PS-40
20
150

93 VMP
15 12V
100

10 PS-40
93 VMP
50

5 24V
0
0

20 25 30 35 40 45 50 55 60
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%
100.00%

Ambient Temp. (ºC)

Appendices
Efficiency (%)

74 Appendices ProStar MPPT Operator’s Manual 75

 APPENDIX C - Wire Sizing Charts
PS-MPPT 25A (mounted vertically on wall)
Charging Current vs. Ambient Temp. 2% Voltage Drop Charts for 75°C Stranded Copper Wire
30
1-Way Wire Distance (feet), 12 Volt System
25 Wire Size
40A 35A 30A 25A 20A 15A 10A 5A
PS-25 (AWG)
31 VMP
Max.
20 12 & 24V 2/0 * 33.6 38.4 44.8 53.8 67.2 89.6 134.4 268.9
Charging PS-25 1/0 * 26.6 30.4 35.5 42.6 53.3 71.0 106.6 213.1
Current 15
62 VMP
(Amps) 12 & 24V 2 16.8 19.1 22.3 26.8 33.5 44.7 67.0 134.0
PS-25
10 93 VMP 4 10.6 12.1 14.1 16.9 21.1 28.1 42.2 84.4
12 & 24V
6 6.6 7.6 8.8 10.6 13.2 17.7 26.5 53.0
5 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
0
20 25 30 35 40 45 50 55 60 12 1.6 1.9 2.2 2.6 3.3 4.4 6.6 13.1
Ambient Temp. (ºC) 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
40A 35A 30A 25A 20A 15A 10A 5A
(mm2)
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-2. Maximum 1-way wire distance for 12 Volt systems, solid

Appendices
copper, 2% voltage drop

76 Appendices ProStar MPPT Operator’s Manual 77

2% Voltage Drop Charts for 75°C Solid Copper Wire *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
1-Way Wire Distance (feet), 12 Volt System
block.
Wire Size
(AWG)
40A 35A 30A 25A 20A 15A 10A 5A Notes:
• The specified wire length is for a pair of conductors
2/0 * 41.7 47.7 55.6 66.7 83.4 111.2 166.8 333.6 from the solar or battery source to the controller (1-way
1/0 * 33.1 37.8 44.1 52.9 66.1 88.2 132.3 264.6 distance)
2 20.8 23.8 27.7 33.3 41.6 55.4 83.2 166.3 • For 24 volt systems, multiply the 1-way length in the table
4 13.1 14.9 17.4 20.9 26.2 34.9 52.3 104.6 by 2.
6 8.2 9.4 11.0 13.2 16.5 21.9 32.9 65.8 • Shaded cells in the table indicate that the current exceeds
8 5.2 5.9 6.9 8.3 10.3 13.8 20.7 41.4
the ampacity of the wire for a given ambient temperature
as defined in the following table:
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 Wire Ampacity** Key

14 1.3 1.5 1.7 2.1 2.6 3.4 5.1 10.3 Exceeds wire ampacity at 60°C ambient temperature
Exceeds wire ampacity at 50°C ambient temperature
Table C-3. Maximum 1-way wire distance for 12 Volt systems, solid Exceeds wire ampacity at 40°C ambient temperature
copper, 2% voltage drop
Exceeds wire ampacity at 30°C ambient temperature

**Ampacity for not more than three

1-Way Wire Distance (meters), 12 Volt System current-carrying conductors in a raceway,
Wire Size
cable, or earth (buried) - Per 2011 NEC
40A 35A 30A 25A 20A 15A 10A 5A
(mm2)

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

Appendices
78 Appendices ProStar MPPT Operator’s Manual 79
2% Voltage Drop Charts for 90°C Stranded Copper Wire 2% Voltage Drop Charts for 90°C Solid Copper Wire

1-Way Wire Distance (feet), 12 Volt System 1-Way Wire Distance (feet), 12 Volt System
Wire Size Wire Size
40A 35A 30A 25A 20A 15A 10A 5A 40A 35A 30A 25A 20A 15A 10A 5A
(AWG) (AWG)
2/0 * 33.6 38.4 44.8 53.8 67.2 89.6 134.4 268.9 2/0 * 41.7 47.7 55.6 66.7 83.4 111.2 166.8 333.6
1/0 * 26.6 30.4 35.5 42.6 53.3 71.0 106.6 213.1 1/0 * 33.1 37.8 44.1 52.9 66.1 88.2 132.3 264.6
2 16.8 19.1 22.3 26.8 33.5 44.7 67.0 134.0 2 20.8 23.8 27.7 33.3 41.6 55.4 83.2 166.3
4 10.6 12.1 14.1 16.9 21.1 28.1 42.2 84.4 4 13.1 14.9 17.4 20.9 26.2 34.9 52.3 104.6
6 6.6 7.6 8.8 10.6 13.2 17.7 26.5 53.0 6 8.2 9.4 11.0 13.2 16.5 21.9 32.9 65.8
8 4.2 4.8 5.6 6.7 8.4 11.1 16.7 33.4 8 5.2 5.9 6.9 8.3 10.3 13.8 20.7 41.4
10 2.6 3.0 3.5 4.2 5.2 7.0 10.5 21.0 10 3.3 3.7 4.3 5.2 6.5 8.7 13.0 26.0
12 1.6 1.9 2.2 2.6 3.3 4.4 6.6 13.1 12 2.0 2.3 2.7 3.3 4.1 5.5 8.2 16.4
14 1.0 1.2 1.4 1.7 2.1 2.8 4.1 8.3 14 1.3 1.5 1.7 2.1 2.6 3.4 5.1 10.3
Table C-5. Maximum 1-way wire distance for 12 Volt systems, stranded Table C-7. Maximum 1-way wire distance for 12 Volt systems, solid
copper, 2% voltage drop
copper, 2% voltage drop

1-Way Wire Distance (meters), 12 Volt System 1-Way Wire Distance (meters), 12 Volt System
Wire Size Wire Size
40A 35A 30A 25A 20A 15A 10A 5A 40A 35A 30A 25A 20A 15A 10A 5A
(mm2) (mm2)
70 * 10.24 11.71 13.66 16.39 20.49 27.32 40.98 81.95 70 * 12.71 14.53 16.95 20.34 25.42 33.90 50.85 101.69
50 * 8.12 9.28 10.83 12.99 16.24 21.65 32.48 64.96 50 * 10.08 11.52 13.44 16.13 20.16 26.88 40.32 80.64
35 5.11 5.84 6.81 8.17 10.21 13.62 20.42 40.85 35 6.34 7.24 8.45 10.14 12.68 16.90 25.35 50.70
25 3.22 3.68 4.29 5.15 6.43 8.58 12.87 25.73 25 3.99 4.56 5.32 6.38 7.97 10.63 15.95 31.89
16 2.02 2.31 2.69 3.23 4.04 5.38 8.07 16.14 16 2.51 2.87 3.34 4.01 5.01 6.69 10.03 20.06
10 1.27 1.46 1.70 2.04 2.55 3.40 5.09 10.19 10 1.58 1.80 2.10 2.52 3.15 4.21 6.31 12.62
6 0.80 0.91 1.07 1.28 1.60 2.13 3.20 6.39 6 0.99 1.13 1.32 1.59 1.98 2.64 3.97 7.93
4 0.50 0.57 0.67 0.80 1.00 1.33 2.00 4.00 4 0.62 0.71 0.83 1.00 1.25 1.66 2.50 4.99
2.5 0.32 0.36 0.42 0.50 0.63 0.84 1.26 2.52 2.5 0.39 0.45 0.52 0.63 0.78 1.05 1.57 3.14
Table C-6. Maximum 1-way wire distance for 12 Volt systems, stranded Table C-8. Maximum 1-way wire distance for 12 Volt systems, solid
copper, 2% voltage drop copper, 2% voltage drop

Appendices
80 Appendices ProStar MPPT Operator’s Manual 81
*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. FOR CURRENT DETAILED CERTIFICATION LISTINGS, REFER TO:
Notes: https://www.morningstarcorp.com/support/library
• The specified wire length is for a pair of conductors from Under, “Type”, choose, “Declaration of Conformity (DOC)”, to
the solar or battery source to the view list of product DOCs.
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

ProStar MPPTTM, MeterBusTM are trademarks of Morningstar

Corporation.
MODBUSTM and MODBUS TCP/IPTM are trademarks of Modbus
IDA.
©2022 Morningstar Corporation. All rights reserved.

MS-001537 v3.5

82 Appendices Certifications 83
 PROSTAR MPPT ADDENDUM TO
OPERATOR’S MANUAL
Hazardous Locations for IECEx/ATEX
Applications
Certifications
IECEx ETL 20.0066X
ALL
ITS20ATEX25933X
COMPONENTS

REACH IECEx: Ex ec ic IIC TX Gc

COMPLIANT ATEX: II 3G Ex ec ic IIC TX Gc
Registration, Evaluation and T4: -40°C ≤ Tamb ≤ +60°C
Authorization of Chemicals
T5: -40°C ≤ Tamb ≤ +45°C

Prostar MPPT must be verified with di-electric strength test
specified by the relevant industrial standard.
The equipment must be placed inside an Ex-rated IP 54
enclosure in accordance with IEC 60079 series. A tool
UL1741 INVERTERS, CONVERTERS, AND CONTROLLERS is required in order to access the equipment inside the
AND INTERCONNECTION SYSTEM EQUIPMENT FOR enclosure.
USE WITH DISTRIBUTED ENERGY SOURCES, SECOND
EDITION, REVISION THROUGH AND INCLUDING SEP 07,
2016
CSA C22.2#107.1-01 POWER CONVERSION EQUIPMENT
UL121201/CSA C22.2 #213 Non-incendive Electrical Morningstar Corporation
Equipment for Use in Class I, Division 2 Hazardous
(Classified) Locations, Groups A,B,C,D, Temperature Group: 8 Pheasant Run, Newtown, PA 18940 USA
T4, T5 (see product manual environmental specifications) 10611 Iron Bridge Road, Ste. L, Jessup, MD 20794 USA

EMC Directives
• Immunity: EN 61000-6-1
• Emissions: EN 61000-6-3
CISPR 22

Low Voltage Directive:

IEC/EN 62109-1 MS-003244-EN-5

1 MORNINGSTAR CORPORATION 2