Morningstar Corporation
Prostar
PWM Charge Controller

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

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

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

Battery Charging
Expanded the battery charging options and capabilities.

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

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

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

Protections
Protection against abuse and faults is now comprehensive.

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

Accuracy
Precision design for improved performance and accurate meter display.

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

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

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

Standard Controller Features:

Note: All our models include a meter!