ProStar MPPT

  • Metered Version

  • Non-Metered Version

  • Bottom Heatsink

  • Terminal Cover Removed

ProStar MPPT

Prostar MPPT™ solar charge controller is an advanced maximum power point tracking (MPPT) battery charger for off-grid photovoltaic (PV) systems up to 1100 watts. All versions include load control and TrakStar™ Technology to maximize PV efficiency and energy harvest.

The ProStar design has been proven in over two decades of use in the world’s most demanding installations—and ProStar today reflects Morningstar’s policy of continuous improvement through regular upgrades and enhancements. Because Morningstar’s employee-owned culture never “rests on success,” ProStar customers can own both a legend and the latest in a single product.

Best of the best. Have used and seen many others. This is the most durable…”

Watch the video to see what makes ProStar MPPT different from the inside out.

Key features and benefits

  • High Reliability – conformally coated circuit board, corrosion resistant terminals, premium high-frequency CoilCraft inductors, over-spec’d components, transient surge suppression, and lowest published failure rate in the industry.
  • Automatic PV Based Lighting Control – field adjustable, multi-event load control enables powerful options for PV lighting systems.
  • Maximizes Energy Harvest – using TrakStar MPPT Technology to determine and adjust to the true maximum power point as solar insolation changes throughout the day.
  • MODBUS Communications – Solar Industry Standard MODBUS communications protocol allows for easy programming, control, remote data access and charge synchronization.
  • SNMP Monitoring – when used with the EMC-1 accessory to enable your network management systems to display key solar power metrics and alert/fault codes.
  • High Efficiency – at low, medium, and high output power levels to maximize energy harvest and minimize heat buildup inside the controller.
  • High Strength – polycarbonate case and extruded aluminum heatsink.
  • Data Logging – up to 256 days of detailed power and load data.
  • Self Diagnostics – continuous monitoring and reporting of any errors through its status LED’s, optional display or communication port.
  • Low Noise Design – meets US Federal Communications Commission Class B specifications.
  • Meter – allows adjustments to charging, lighting, and load control settings without a computer.
  • Fanless design for long-term reliability–no moving parts to fail, no dirt and debris sucked into the controller, and no parasitic load to reduce efficiency.
A. Premium high-frequency CoilCraft surface mount inductors

They’re worth it, because they provide the faster power « tracking » that lets us engineer this much power and control into a compact design.

B. High-frequency design

Combined with premium, « over-spec’d » components, this greatly improves control response which guards against system transients, regulation overshoot and overcurrent/overload conditions

C. Built-in 4500W Transient Voltage Surge Suppression for lightning protection

Nature do your worst–this controller can take it

D. Large diameter, high torque, corrosion resistant terminals

If you’ve ever trashed a lesser terminal during an installation, you’ll appreciate some « overkill » here

E. DirectFET™ MOSFET power devices

Allows the surface-mounting of critical components underneath the main board next to the heat sink, which reduces heat travel distance and keeps the controller even cooler

F. Highly-conductive aluminum heatsink extrusion

As opposed to cast aluminum, which is less effective in passive cooling applications

G. Communications/data port with serial/meter auto detect

« Talks solar » with standard industry language, for system monitoring and cloud connectivity-speaks Modbus, and SNMP (with the EMC-1)

H. Lithium foldback circuit

Lithium batteries are expensive and vulnerable to cold temperatures. When it gets close to freezing, the controller backs-off charging to avoid damaging batteries

I. High-speed ARM processor

All-digital calibration for high accuracy, using the same efficient technology found in advanced mobile device

J. TrakStar™ Technology

Morningstar’s hallmark MPPT technology precisely seeks and locks onto the true maximum power point quickly and accurately, to ensure the highest output possible from a solar array

K. Large format, high-resolution backlit LCD

When you’ve been in the field installing, you appreciated being able to read a crisp, high contrast display on site

L. 5 year warranty

Up to 2 1/2 times longer than some competitors in this class

M. Self-diagnostics

ProStar is smart enough to monitor and analyze system performance, and alert you when you need to know

N. High temperature architecture

Heat is the enemy of all electronics. That’s why Prostar’s critical components are rated to withstand temperatures right up to the boiling point of water (100°C)

O. Lexan polycarbonate UL listed case

Protects the precision electronics inside with an impact strength 30 times greater than the acrylic thermoplastics commonly found on lesser controllers

P. Cooling Fan

Just kidding. We’ve never needed them

Specifications and Certifications

Model PS-MPPT-25 PS-MPPT-25M PS-MPPT-40 PS-MPPT-40M
*Input power can exceed Nominal Operating Power. Controller will limit and provide its rated continuous maximum output current into batteries.
Charge Rating 25 amps 25 amps 40 amps 40 amps
Max. PV Open Circuit Voltage (Voc) 120 volts 120 volts 120 volts 120 volts
Nominal Battery Voltage 12V or 24V 12V or 24V 12V or 24V 12V or 24V
Nominal max. Operating Power* - 12 volt battery 350W @45C 350W @45C 550W @45C 550W @45C
Nominal max. Operating Power* - 24 volt battery 700W @60C 700W @60C 1100W @60C 1100W @60C
Peak efficiency 98% 98% 98% 98%
Battery Voltage Range 10-35V 10-35V 10-35V 10-35V
Voltage Accuracy <=0.1% +/- 50mV <=0.1% +/- 50mV <=0.1% +/- 50mV <=0.1% +/- 50mV
Operating Temperature Range -40 C to +60C -40 C to +60C -40 C to +60C -40 C to +60C
Warranty 5 Years 5 Years 5 Years 5 Years
Built-in meter Yes Yes
CE and RoHS compliant Yes Yes Yes Yes
IEC 62109 Yes Yes Yes Yes
ETL Listed [UL-1741 and Canadian CSA C22.2 No.107.1.01] Yes Yes Yes Yes
FCC Class B Part 15 Compliant Yes Yes Yes Yes
Manufactured in a Certified ISO 9001 Facility Yes Yes Yes Yes

Datasheets

Download the ProStar MPPT Solar Charge Controller Datasheet.

Operation Manuals

Download the ProStar MPPT Solar Charge Controller Manual.

Videos

ProStar MPPT Controller - 4 minute video

This short video highlights the high quality of the ProStar MPPT solar charge controller, and its ability to regulate charging of lead acid, lithium, or nickel cadmium batteries in off-grid solar applications. The video also addresses lighting control, self-diagnostics, data logging, MODBUS communications, array oversizing, and low noise design.

Morningstar Charging Experts featuring ProStar MPPT

This 5 minute video highlights the ProStar MPPT solar charge controller’s circuit board that differentiates it from other brands. In addition to the capacitors, inductors, processors, surge protectors, and other over-spec’d internal components, the quality of the controller’s heat sink and outer casing is also addressed. The video concludes with mention of features and capabilities related to communications, datalogging, lithium battery charging, and high quality and reliability.  

New ProStar MPPT Solar Charge Controller

Recorded Webinar

This 30 minute recorded webinar gives a more in depth overview of how the ProStar MPPT solar charge controller fits into the existing Morningstar portfolio. The recording also includes answers to questions about operating temperatures, the display meter interface, and protections, faults and alerts.

Applications

  • Eclairage

  • Hydro @fr

  • Pétrole et gaz

  • Railroad Signaling @fr

  • Résidentiel

  • Transport et circulation

Accessories

Sorry, we currently do not have any compatible products. Please check back soon.

Firmware

It’s a recommended best practice to install your product’s latest firmware to ensure access to all up-to-date features, accessory compatibilities, and code modifications. Watch this 5 minute video for instructions on how to download and update ProStar MPPT firmware.

After watching the video, click here and go to the software tab to access and download the firmware.

System Diagrams

    Off-Grid Diagram with DC Load

The schematic diagram above, illustrates how the ProStar MPPT regulates power to batteries and a direct current (DC) load in an off-grid system.

  1. Sunlight contacts the solar modules, which convert solar into DC electrical power that it delivers to a charge controller.
  2. The charge controller regulates the amperage and voltage that is delivered to the loads and any excess power is delivered to the battery system so the batteries maintain their state of charge without getting overcharged.
  3. During the evening when there is no sunlight, battery power is used to run the load.

 


 

    Off-Grid Diagram with AC Load


The schematic diagram above, illustrates how the ProStar MPPT regulates power to batteries and an alternating current (AC) load in an off-grid system.  This diagram is very similar to the DC load diagram above it except an inverter has been added.

  1. Sunlight contacts the solar modules, which convert solar into DC electrical power that it delivers to a charge controller.
  2. The charge controller regulates the amperage and voltage that is delivered to the battery system so the batteries maintain their state of charge without getting overcharged.
  3. Batteries deliver power to the inverter which converts DC to AC power that it delivers to the load.  Notice that  the inverter is connected to the battery, not the controller’s load terminals, like we did in the DC load example.  That’s because the inverter can have a high energy surge upon start up, and this high current surge might be higher than the rated capacity of the charge controller, whereas the batteries will be able to meet the high energy surge requirement.