Plasmatronics PL20, PL40, PL60 Reference Manual

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Page 1

Rev 1.0 25.07.07

PL20N Reference Manual

Plasmatronics PL Series

Reference Manual

Advanced Solar Charge Controller

Page 2

Rev 1.0 25.07.07PL20N Reference Manual

Contents

Introduction .......................................................................................... 4

Additional Installation Notes ........................................................................... 4

Features ........................................................................................................... 5

Overload Protection ....................................................................................... 5

Thermal Protection ......................................................................................... 5

Menus .............................................................................................................. 5

1.0 BATV Menu .................................................................................... 6

The Regulation Cycle ..................................................................................... 6

1.1 BOST (Boost) ........................................................................................... 6

Returning to Boost state .......................................................................... 6

1.2 Equalise (optional) .................................................................................... 7

1.3 ABSB (Absorption) ................................................................................... 7

1.4 FLOT (Float) ............................................................................................. 7

2.0 CHRG Menu .................................................................................... 8

CHRG ............................................................................................................. 8

CINT .............................................................................................................. 8

CEXT ............................................................................................................. 8

Generator Control ......................................................................................... 8

GSET ........................................................................................................ 8

GMOD ..................................................................................................... 9

GEXD (Generator Exercise) ................................................................... 10

GDEL (Generator changeover delay) .................................................... 10

Generator Example ................................................................................ 10

3.0 LOAD Menu ................................................................................. 12

LOAD ........................................................................................................... 12

LINT ............................................................................................................. 12

LEXT ............................................................................................................ 12

Low Battery Disconnect (LSET, LOFF, LON, LDEL) ..................................... 12

4.0 IN Menu ........................................................................................ 13

IN ................................................................................................................. 13

IN/INT .......................................................................................................... 13

IN/EXT ......................................................................................................... 13

5.0 OUT Menu .................................................................................... 13

OUT .............................................................................................................. 13

OUT/INT ..................................................................................................... 13

OUT/EXT .................................................................................................... 13

6.0 DATA Menu (Retrieving Performance Data) .............................. 14

6.1 & 6.2 VMAX & VMIN ............................................................................. 14

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6.3 FTIM (Float time Display) ....................................................................... 14

6.4 SOC (State of Charge Display) ............................................................... 15

6.5 TEMP (External Battery Temperature Sensor Display) .......................... 16

Setting Lockout .................................................................................. 16

6.6 SOLV (Solar Voltage Display) ................................................................. 16

6.7 HIST (History display) ............................................................................ 16

7.0 SET menu .................................................................................... 17

7.1 TIME ....................................................................................................... 17

7.2 VOLT ...................................................................................................... 17

7.3 PROG (Adjusting Regulation Settings) .................................................... 17

Program Function Table (Generic Programs) ......................................... 17

Program Description ............................................................................. 17

Settings Used in Programs 0-3 ............................................................... 18

Settings for Program 4 ........................................................................... 18

7.4 REG menu (Customising Regulation Settings) ........................................ 19

7.4.1 HYST (Hysteresis Value) ................................................................ 19

7.4.2 Charge Current Limit ................................................................... 20

7.4.3 TCMP (Temperature compensation) ............................................ 20

Connecting a Temperature Sensor .................................................. 21

7.5 MODE Menu (Adjusting Configuration Settings) ................................... 22

7.5.1 & 7.5.2 LSET & GSET ................................................................... 22

Shunt Control ................................................................................... 24

7.5.3 BSET: Configuring B- Sense Input .................................................. 24

7.5.4 BAT2 - Second battery control ..................................................... 26

7.5.5 PWM and Slow Switching .............................................................. 27

7.5.6 BCAP ............................................................................................ 28

7.5.7 ALRM ............................................................................................ 28

7.5.8 RSET .............................................................................................. 28

7.6 EVNT Menu (Event Control) ................................................................. 29

Using the Event Controller .................................................................... 29

Examples: ............................................................................................... 33

A.0 Appendices .................................................................................. 34

A.1 ‘Catch diode‘ protection ........................................................................ 34

A.2 Accessories ............................................................................................ 34

A.3 Specifications on PL20, 40, 60 ................................................................ 35

A.3.1 Block Diagram of PL20/40 Hardware .......................................... 36

A.3.2 Block Diagram of PL60 Hardware ............................................... 36

A.4 Thermal derating ................................................................................... 37

A.5 Mechanical Information .......................................................................... 38

Programs 0-3 Menu System .......................................................................... 40

Program 4 Menu System (for custom settings) ............................................. 41

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Introduction

Please read the User Guide before reading this manual.

In most cases, the User Guide provides all the information needed for effective installation of the PL, and there is no need for the user to read this Reference Manual.

Some users will require further information. This manual provides a detailed technical description of the operation of the controller. This manual assumes more technical knowledge than the User Guide.

If you are in any doubt, it is recommended you do not adjust the advanced settings described in this manual. Incorrect adjustment may reduce the effectiveness of your PL and could damage your battery.

All voltage values used in this manual assume a 12V system. Scale voltages for other system voltages (e.g. 24V system = voltages x 2, 48V system = voltages x 4)

Additional Installation Notes

Ensure that you have followed the installation instructions on pages 3-5 of the User Guide. The PL can be used for system voltages of up to 48V. It is safe to connect the power before setting the system voltage, even with a 48 volt battery.

Always mount the PL vertically with clear airflow around the fins. In hot conditions, do not put the PL in a sealed enclosure, as this will restrict the airflow around it. Do not install the PL in direct sunlight in hot conditions - the heatsink may reach over 70°C in some environments.

The PL is specified for up to a maximum 55°C ambient temperature. At full power, in high temperature ambients, the LCD display may occasionally reach a high enough temperature to become darker and may become unreadable. It will return to normal when it cools down.

1ntro







BO OS T

PL20N

Charge Controller

Dis play

But ton

Ala rm l ed

Low lev el con nect ions (pl ug i n ter mina l blo ck)

Ser ial bus

por t

Hig h cu rren t con nect ions

Mou ntin g ho les

Cab le t ie

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Test

ter mina l

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PL20N Reference Manual

Features

The PL series of solar controllers are exceptionally versatile. They give the user unparalleled capability to adjust the function of the controller and to monitor the performance of the energy system.

To cater for both non technical and technical users, the PL has four preset programs which can be used without needing to understand the details of its operation. For those with a good understanding of power regulation, there is another program, which allows all the settings to be adjusted if required.

Once the program has been selected, it is possible to disable any further adjustment. This prevents unauthorised adjustment of settings.

Although the PL is primarily a device to control the charging of batteries from solar electric (photovoltaic) panels, it can also be used with other energy sources such as wind, microhydro and fuel driven generators.

The PL can support a variety of regulation methods. It supports slow speed switching and fixed frequency pulse width modulation (PWM) control in series and shunt modes.

Low battery voltage load disconnection is provided, as are an alarm, facility to control the charging of a second battery bank, control for a back up generator and an event controller which can be used to control lights, pumping, waste energy use and other timer functions.

A temperature sensor can be added to correct the regulation voltages for battery temperature.

There is an input for measuring external voltages.

A serial interface is provided for accessories including remote shunt adapters (XLS) and an RS232 adapter to communicate with a computer/ modem (XLI).

Using external current shunts attached to the XLS allows the controller to see other current flows in the system.

The PL can control larger systems by adding external switch blocks attached to the serial bus

The XLI allows remote monitoring and adjustment. Custom settings can be stored on a computer and uploaded into the PL controller. Data from the PL can be downloaded into the computer and displayed easily.

Overload Protection

The PL has over current protection on both the load and charge switches.

If the user accidently short circuits the load or the charge connections, then the switch will turn off very quickly before any damage is done to the switch.

If the user overloads the load switch, then the load switch will disconnect after a period of time to protect itself from overheating. It will reconnect automatically once the switch cools

If the charge input is overloaded, then the controller will turn the charge switch off, as required to reduce the average current to the rated charge current of the PL

For details see section x.x.

Thermal Protection

The PL has a temperature sensor on the circuit board. The function of this sensor is to tell the PL how hot it’s own circuit board is so that it can reduce the charge current (the major heating source) in order to protect against overheating.

Menus

The PL has a simple main menu. This is described in the user guide and provides most the the information required for normal use.

Behind each of the main menu screens are sub menus. These are entered by doing a long push in the main menu. They allow access to more information and control of more advanced features.

The following pages describe each submenu in detail.

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1.0 BATV Menu

The BATV screen, shown at power-up, displays the real-time battery voltage.

A long push on the BATV screen will display the state of the charge regulation cycle.

The Battery Charge Cycle

The PL’s sophisticated regulation system is designed to keep the battery fully charged without overcharging it.

To achieve this, it uses a charge control process with three main states. These states are Boost, Absorption and Float. The PL also uses a fourth state from time to time, called the Equalisation state (See fig 2B.)

1.1 BOST (Boost)

In the boost state, all the charge current available is used to charge the battery. As the battery charges, its voltage rises. When the voltage reaches the boost maximum voltage (BMAX) and remains there for 3 minutes, the controller will automatically advance to the absorption state and then, later, to the float state.

Returning to Boost state

To get this charge cycle to repeat, the PL must return to the boost state. There are three ways that it can do this.

a. Low Battery Voltage

If the battery voltage falls below the boost return voltage BRTN for more than 10 minutes, then the PL will switch back into the boost state. The delay is necessary to prevent large short term loads causing unnecessary returns to Boost.

b. Programmed boost cycles (optional)

The PL will automatically do a boost cycle after a set number of days (BFRQ), regardless of battery voltage.

c. Manual boost

The user can manually set the PL into the boost state (or any of the regulation states).

To manually advance to the next state, do a long push on BATV. This will show the current regulator state. (BOST=Boost, EQUL=Equalise, ABSB=Absorption, or FLOT=Float). A longpush on that state will manually advance the PL into the next state. Or, to return to the BATV screen without changing the state, do a short push.

BATTERY VOLTAGE

TIME

BOOST EQUALISATION ABSORBTION FLOAT BOOST

BRTN

FLTV

ABSV

EMAX

BMAX

ETIM

ATIM

Fig. 1B - The Battery Charge Cycle

BOST EQUL ABSB FLOT

BATV

CHRG

LOAD

OUT

DATA

SET

Fig. 1A - The BATV Menu Structure

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PL20N Reference Manual

Note: if ETIM is 0, then the Equalise state will be bypassed. If ATIM is 0, then the Absorption state will be bypassed.

On the BOST and FLOT displays, the battery voltage is shown. On the EQUL and ABSB displays, the time on the equalisation or absorption timer is displayed. When this time reaches the set time (ETIM or ATIM) the PL will advance to the next state. Remember that the timers will stop if the voltage falls too far below the set point.

1.2 Equalise (optional)

Many battery manufacturers recommend that the battery bank be given an overcharge occasionally. This is a deliberate overcharge, designed to equalise the voltages and specific gravities of all the cells in the bank by bringing them all up to full charge and to stir up the electrolyte in liquid cells to reduce stratification.

The PL supports an automatic programmed equalisation. This state allows the battery voltage to rise until it gets to the equalisation voltage EMAX and then remain at this voltage for the set equalisation time ETIM. This equalisation is done every EFRQ days. (Typically 30-60 days). Equalisation will begin at 9am on the appropriate day. If ETIM is 0, then equalisation will not occur.

To prevent the controller being trapped in equalise mode for a long time because there is inadequate charge current to reach the equalise voltage, the PL terminates equalise after 4 days

1.3 ABSB (Absorption)

In this state, the PL tries to keep the battery voltage constant while the last part of the battery charging occurs. This prevents excessive gassing which occurs at high cell voltages. The PL will keep the battery voltage at the absorption voltage ABSV until it has been at this voltage for the absorption time ATIM. When the absorption time is finished, the PL advances to the Float state.

If there is a cloudy period and there is insufficient charge current to keep the voltage up to ABSV, then the absorption timer will stop and resume when the voltage comes back up to ABSV.

To allow some margin, the timer actually runs if the voltage is above ABSV-HYST. (HYST is the hysterisis setting used for slow speed switching

-usually about 0.4V))

1.4 FLOT (Float)

In this state, the battery has been fully charged. The charge current is now used to keep the battery voltage at a level which maintains full charge. This voltage (FLTV) should be below the gassing voltage to avoid excessive electrolyte loss. If charge is drawn from the battery, the PL will allow charging to resume until the battery returns to FLTV.

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2.0 CHRG Menu

CHRG

The CHRG screen gives the real-time total charging current (Amps). This total is the sum of solar charge current (CINT) and any external charge current. This may be current from an external switchblock or MPPT device connected to the bus or an external current measured using a current shunt and an XLS.

CINT

From the charge screen, a long push displays CINT (Charge Internal). This is the real-time solar charging current flowing into the SOL+ terminal. (measured in amps.)

External Charge

From the CINT screen, a short push displays the current reading from any external device attached which can measure current. If the device is a maximum power point tracker (MPPT) then this device is shown as MPTx,

where x is the device number. Similarily, for switchblocks the display is SWHx and for shunt adaptors, SHNx. The device number can be from 1 to 4 for shunt adaptors and from 1 to 12 for MPPT or Switchblocks. To fit the display, numbers greater than 10 are given letters. So 10 is A, 11 is b and 12 is C.

This list also allows the user to check that the PL has found or ‘discovered’ all the external devices attached to the bus. This discovery process is automatic. If a device is not on the list and should be, then refer to section xx for troubleshooting advice.

Generator Control

The PL has a comprehensive generator controller built in. It works in a similar way to the Low Battery Disconnect function. It is designed to give a run or stop signal to an electronic start generator. It does not handle the actual generator start-up sequence - this should be done by the generator itself.

BATV

CHRG

LOAD

OUT

DATA

SET

CINT External

GSET T

oggle function status on / off

GMOD Set generator control mode

G ON G ON G ON Set Voltage / SOC% to start generator

GOFF Set SOC% to stop generator

GOFF GOFF

Set Voltage to stop generator

GDEL GDEL

Set delay before on/off change

SOC% SOC%

State Of Charge (SOC) Long push to reset (100%)

GEXD

GEXD GEXD Set days between generator exercises

GRUN GRUN GRUN GRUN Set length of generator exercise

AY GDAY GDAY View/change number of days since last exercise

(or run time if generator running)

0 or 4

1 or 5

2 or 6

Fig. 2A - Generator Control Menus (PROG=4 only)

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GSET

In the GSET screen, a long push will manually change the state of the generator output. The GEN indicator at the bottom of the screen is visible when the generator function wants the generator to be running. Note: the Generator will not turn on during the ‘quiet time’, if selected. (see below)

GMOD

The generator can operate in four different modes. The generator mode is selected in the GMOD screen and can be 0-6.

Quiet time: In modes 0,1 & 2, the generator is not allowed to operate from 9pm until 9am so as to enforce a ‘quiet time’.

Modes 4-6 are the same as modes 0-2 except that there is no quiet time.

Note - do not confuse the GSET described in Figure 2A with the screen of the same name described in Section 7.5.2. which sets the G terminal function.

GEXD (Generator Exercise)

To prevent the generator from seizing up, it is good practice to exercise the generator periodically. The PL supports this with an

Quiet Time M* No Quiet Time

GMOD: 0 1 2 3 4 5 6 Name Description Range

• • GON Set V to start generator 10-12.5V

• • • • GON Set SOC% to start generator 0-99%

• • • • GOFF Set V to stop generator 11.0-16.5V

• • GOFF Set SOC% to stop generator 1-125%

• • • • GDEL Set delay before on/off change 1-15 min

• • • • SOC% Current SOC% Long push to reset to 100%

0-127%

• • • • • • GEXD Set days between generator exercise

2-60 days

• • • • • • • GRUN Set length of generator exercise 0-4.0 hrs

• • • • • • GDAY View/change # of days since last exercise

2-60 days

• = Active Parameter for relevant generator mode (GMOD) *M = Manual GMOD = GMOD Settings

Mode# Description

0. Turn on when battery voltage falls to G ON for GDEL minutes. Turn off when the voltage rises to GOFF for GDEL minutes. Quiet time applies.

1. Turn on when the State of Charge (SOC%) falls to G ON % of the battery capacity. Turn off when the voltage rises to GOFF for GDEL minutes. Quiet time applies.

2. Turn on when SOC % falls to G ON%. Turn off when SOC% rises to GOFF%. (GOFF% can be set to greater than 100% to allow some overcharge.) Quiet time applies.

3. Manual start. When started (in the GSET screen) the generator will run for GRUN hours.

4. No quiet time. Turn on when battery voltage falls to G ON for GDEL minutes. Turn off when the voltage rises to GOFF for GDEL minutes.

5. No quiet time. Turn on when the State of Charge (SOC%) falls to G ON % of the battery capacity. Turn off when the voltage rises to GOFF for GDEL minutes.

6. No quiet time. Turn on when SOC % falls to G ON%. Turn off when SOC% rises to GOFF%. (GOFF% can be set to greater than 100% to allow some overcharge.)

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automatic generator exercise function, which will turn on every GEXD days. The number of days since the last exercise is shown on the GDAY screen. The generator will run for GRUN hours. When running, the elapsed time is shown on the GTIM screen. Both GDAY and GTIM can be adjusted.

Note:

There is no generator exercise when GMOD = 3 (manual start).

GSET toggle does not work during generator exercise A small amount of overcharge will occur if battery is already fully charged. Use a low GRUN value if this is of concern.

GDEL (Generator changeover delay)

A programmable delay (in minutes) is used to prevent false turn on or off of the generator due to large transient loads. Default setting is 10 min.

Generator Example

The generic programs (PROG=0-3) use voltage driven generator control (GMOD=0). See “settings used in Programs 0-3” for on-off voltages etc.

For example, if SOC% triggered generator on, voltage-triggered generator off, and no quiet time, is desired, set up the regulator as follows:

PROG = 4 Allows user adjustment.

GMOD = 5 SOC % ON, Voltage OFF,

no quiet time

CHRG menu : Set GON, GOFF, GDEL,

GEXD, GRUN as required

SET/REG : Check these settings are

correct for your battery type

Mode menu :

LSET = 2

GSET = 2

LSET if using LOAD terminal for generator control GSET if using ‘G‘ terminal for generator control

Note: when changing from prog 0-3 to program 4, the user can load the default settings for program 1 into the PL using the DFLT screen in the MODE menu. See section x.x This can save a lot of time.

Generator Control

For many generators it is possible to control their operation remotely. This is either a remote start or run function built into the generator or a seperate remote start unit.

There is usually a pair of contacts that will cause the generator to run if they are closed. This can be done with a switch or a relay.

The PL provides a G relay which can be used for this purpose. This relay is voltage free and solid state. It can carry a current of up to 300mA and can block 85V.

For some generators it is possible to connect the G relay directly to the remote start input on the generator. The wiring for this is shown in fig 2B.



 

BOO ST

B- B- B- S+ B+ L+

Generator Remote Start Unit

Generator controlled directly by the G relay

Fig. 2B - Generator start relay wiring

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PL20N Reference Manual



 

BOO ST

B- B- B- S+ B+ L+

Generator Remote Start Unit

G relay switches a larger relay

Intermediate Relay

Fig. 2C - Generator start wiring with an intermediate relay.

This direct connection will work if the current flowing through the remote start terminals is less than 300mA. If the current is greater than this, then it will be necessary to use an intermediate relay with a higher contact current rating. The G relay switches the intermediate relay which in turn switches the remote start terminal. The wiring for this is shown in fig 2C.

Chose a relay with a conact current rating suitable for the remote start unit and a coil voltage which is the same as the system voltage. The relay coil should not draw more than 300mA when it is energised. Be careful with automotive relays because they can often be poor relays requiring large coil currents. Use relays from the electronics industry which generally have lower drive power.

The G relay terminals do not need a catch diode across the relay coil to protect from the flyback voltage. This protection is built into the G terminal.

It can be difficult to determine what current is required to operate the remote start. The best way to do this is to measure it. Short the remote start terminals with a multimeter on its current range and measure the current.

The manufacturer’s manual should contain this information but often does not.

The generator control provided by the PL is simple

-a contact closure is provided when the generator should run and the contacts open when the generator should be stopped. It does not handle the issues associated with starting such as fuel and what to do if the generator does not start. This should be handled by the remote start unit.

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3.0 LOAD Menu

Low Battery Disconnect

(LSET, LOFF, LON, LDEL)

To prevent battery damage due to overdischarge, the PL has a function which can turn off the load if the battery voltage falls too low.

If correctly configured, equipment connected to the battery (the “load”) will be turned off when the battery voltage falls below the LOFF voltage for LDEL minutes. Once turned off, the load will not be reconnected until the voltage rises above the L ON voltage for LDEL minutes. The L ON voltage should be set high enough so that some recharge will have taken place before reconnection, otherwise the disconnection process can oscillate.

This feature is optional, and can be disabled either by connecting the user load directly to the battery, or by setting LOFF low enough so that the low battery disconnect function never activates.

The LOAD indicator at the bottom of the screen is visible when the low battery disconnect function wants to disconnect the load. (Note that other settings can override the function, so the LOAD indicator does not necessarily mean that the power actually has been disconnected from the load.) Also, the alarm led will flash at a 2 second rate when the disconnect timer has begun to timeout. If the load disconnect function operates, then the alarm led stops flashing and turns fully on.

The Low Battery Disconnect function can also be toggled manually by a long push when in LSET menu (see Figure 3A).

Name Description Range

LOFF Set voltage at which load

disconnects

10.0-12.5 V

LON Set voltage at which load

reconnects

11.0-16.0 V

LDEL Set delay before

switching on/off

0-15 min

BATV

CHRG

LOAD

OUT

DATA

SET

LINT External

LSET Toggle low battery

LOFF Set voltage at which

L ON Set voltage at which

LDEL Set delay before

load disconnects

load reconnects

disconnect status on/off

switching

LOAD

The LOAD screen gives real-time total load current (in Amps). This total is the sum of the current flowing through the load terminal (LINT) and any external load current. This may be current from an external switchblock or an external current measured using a current shunt and an XLS.

LINT

From the LOAD screen, a long push displays LINT (Load Internal). This is the real-time load

Fig. 3A - LOAD Menu

current used by equipment connected to the regulator’s LOAD terminal.

External Load

From the LINT screen, a short push displays the load current reading from any external device attached which can measure current. If the device is a maximum power point tracker (MPPT) then this device is shown as MPTx, where x is the device number. Similarily, for switchblocks the display is SWHx and for shunt adaptors, SHNx. The device number can be from 1 to 4 for shunt adaptors and from 1 to 12 for MPPT or Switchblocks. To fit the display, numbers greater than 10 are given letters. So 10 is A, 11 is b and 12 is C.

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5.0 OUT Menu

OUT

The OUT screen gives a running total of Amp hours (Ah), or energy, that has been used during the day (since midnight). This total is the sum of Ah used by equipment connected to the LOAD terminal and any external devcies.

OUT/INT

From the OUT screen, a long push displays INT (Internal Ah OUT). This is the running total of Ah used by equipment connected to the regulator’s LOAD terminal. A long push will clear this total.

OUT/External

From the INT screen, a short push displays any external load Ah. Long push to clear.

Note: the net battery Ah is the IN Ah -OUT Ah.

The IN and OUT Ah counters are reset each day at midnight.

INT External

Clear

BATV

CHRG

LOAD

OUT

DATA

SET

INT External

Clear

BATV

CHRG

LOAD

OUT

DATA

SET

Selecting a load switch

The low battery disconnect is an internal logical function. To do something other than act as a warning, it has to be used to control a load switch.

This can be done in three different ways. It can control the PL’s LOAD terminal, or the G (General Purpose Output) relay or an external switchblock attached to the bus. The sense of its operation can also be reversed, i.e. it can turn on the terminal when the function decides the load should be disconnected. This can then be used as a low battery alarm or to drive a relay to turn off other loads.

The connection to real switches is set up in the MODE menu. See section 7.5 for details.

DO NOT CONNECT AN INVERTER OR ANOTHER BATTERY TO THE LOAD TERMINAL. This terminal is rated at 20A. Most inverters draw larger currents than this and have their own low battery cut off circuitry anyway. In general, Inverters should be connected directly to the battery.

Fig. 4A - IN Menu

Fig. 5A - OUT Menu

4.0 IN Menu

The IN screen gives a running total of Amp hours (Ah), or energy, that has been put into the battery during the day (since midnight). This total is the sum of Solar Ah collected directly through the PL and any measured external Ah input.

IN/INT

From the IN screen, a long push displays INT (Internal Ah IN). This is the running total of Ah collected through the SOL terminal over the day (since midnight). A long push will clear the INT running total.

IN/External

From the INT screen, a short push displays any external Ah contributions. This is the running total of each external Ah input from MPPT, Switchblock or current shunt measurements. A long push will clear a total.

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Fig. 6A -The DATA Menu Structure

6.0 DATA Menu

(Retrieving Performance Data)

A long-push on DATA, enters the data menu. This displays performance information for the current day. The screens in the DATA menu have the following meanings:

VMAX maximum battery voltage since midnight.

VMIN minimum battery voltage since midnight.

FTIM time of day the regulator entered the

Float state.

SOC estimated state of charge of the

battery based on the amp hours in and the amp hours out. A very rough ‘fuel gauge’ -see below for further details.

TEMP temperature being sensed by the

external temperature sensor (if attached).

SOLV solar panel voltage (open circuit)

HIST entry point for history data.

changed from the ABSB (Absorption) state to the FLOT (Float) state.

This time will only be recorded if the regulator has done a transition into float that day. A time will not be recorded (i.e it will be zero) if the controller did not reach the float state or stayed in float all day.

6.4 SOC (State of Charge Display)

SOC (State Of Charge) should be read as a percentage estimate of how full the battery is.

This estimate is based on the amp hour balance counter. The counter keeps a running balance of amp hours in vs amp hours out. The SOC display shows this balance as a percentage of the battery size. Note that all system currents must be monitored by the regulator and the battery capacity must be entered by the installer at the BCAP setting before SOC will be meaningful.

Over time, the amp hour balance counter will drift out of line with the real battery state of charge. To realign the counter the PL automatically makes two corrections:

When the regulator state changes from Absorb to Float AND the charge duty cycle is less than 25%, SOC is reset to 100%.

SOC is capable of reading more than 100%, however as soon as 1Ah of discharge is recorded it will be set back to 100%, thus

SOC (%) =

BCAP

BCAP + Ah IN - Ah OUT

x 100

BATV

CHRG

LOAD

OUT

DATA

SET

VMAX VMIN FTIM SOC TEMP SOLV HIST

Toggle setting lockout

("A" showing means setting adjustable)

At midnight, VMAX, VMIN, FTIM, SOC, IN and OUT are stored in the history data and cleared from the current day readings.

6.1 & 6.2 VMAX and VMIN

VMAX and VMIN respond very slowly to changes in battery voltage. This allows them to ignore short term voltage fluctuations. A long push will reset the value to the current battery voltage.

6.3 FTIM (Float time Display)

FTIM indicates the time of day that the regulator

discarding any surplus amp hours. These amp hours were really put into the battery, but the battery cannot be more than 100% full. The difference is mostly the inherent loss in the battery. The battery is not 100% efficient.

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A long push on the SOC screen will reset the SOC to 100%.

The SOC figure should be treated with caution, as there are several reasons that it may be inaccurate:

The PL does not automatically have knowledge of the whole system. It only knows what you tell it. For SOC to work at all, the PL must be measuring all charge (Ah in) and discharge (Ah out). If the battery can charge or discharge without the PL knowing, SOC will not be meaningful.

Variations in charge efficiency mean SOC will tend to be a little optimistic.

The effective capacity of the battery reduces with age. BCAP should be reduced in older batteries to adjust for this.

When you set up BCAP on installation, you should choose your best guess of the batteries actual capacity when used in the way you intend to use it. For example, if you think the battery will mostly be charged and discharged at around the 100h rate (C/100) you should set the capacity of you battery at the 100h rate from the manufacturer’s literature. If you expect the battery to be used at various charge and discharge currents, try to estimate an average. In many systems it is more accurate to use the C/20 rate.

Battery self discharge and variations in temperature will also cause some inaccuracy.

6.5 TEMP (External Battery Temperature Sensor Display and Setting Lockout)

This screen displays the external battery temperature sensor reading (if attached) or “0.0” if it’s not.. It is also used to adjust Setting Lockout (see figure 6.A).

Setting Lockout

In some cases it is desirable to restrict the ability to adjust settings, so as to prevent unwanted tampering.

To disable settings, long push on the TEMP

•

screen. The “A” indicator will disappear. A useful memory aid is to consider that “A” stands for “Adjustable” on this screen.

To enable adjustment of settings again, long push on the TEMP screen again. If you have successfully enabled settings adjustment, the “A” will reappear while TEMP is showing.

The controller remembers the state of the settings lockout when the power is disconnected.

6.6 SOLV (Solar Voltage Display)

This screen displays the open circuit solar panel voltage

The charge current through the SOL terminal is turned off while the PL is displaying this screen. If the view is left on the SOLV screen, the panels will be reconnected when the screen goes to sleep (failsafe).

6.7 HIST (History display)

Six pieces of data are recorded each day. These are:

Total Ah IN for the 24hrs. This is a measure of the energy collected that day

Total Ah OUT for the 24hrs. This is a measure of the energy used that day.

VMAX - the maximum battery voltage that day.

VMIN -the minimum battery voltage that day,

FTIM - time of day the controller changed to float mode. ( 0 if it didn’t

SOC. -the state of charge at the end of the day

These figures are a very good guide to how well the solar system is performing. The user can compare the energy collected with the energy used and get some feedback about the balance between collection and use.

These records are available for the past 99 days. on the screen of the controller. The controller actually keeps records for over one year, but for practical reasons, these can only be accessed via the computer interface. The records are not lost if the power is disconnected.

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At the start of each day record is the DAY screen. This shows which day’s data you are looking at (DAY 1 = yesterday, DAY 2 = the day before yesterday, etc.)

For help with navigating through the History, refer to Fig.6B.

A long push on each of the screens except EXIT will move down to the next day or the next day’s value. Short pushes move between figures for the same day.

NEXT goes to the next day, BACK goes to the previous day. The day numbers wrap around when they reach the end.

A short push on the EXIT screen will take you back to the beginning of that day’s record. A long push will exit back to the DATA screen.

Thin arrow = short push Thick arrow = long push

BATV

CHRG

LOAD

OUT

DATA

SET

DAY 1 IN OUT VMAX VMIN FTIM SOC NEXT BACK EXIT

DAY 2 DAY 30 DATA

VMAX VMIN FTIM SOC TEMP SOLV HIST

DAY 2 IN OUT VMAX VMIN FTIM SOC NEXT BACK EXIT

DAY 3 DAY 1 DATA

DAY 3 IN OUT VMAX VMIN FTIM SOC NEXT BACK EXIT

DAY 4 DAY 2 DATA

DAY 30 IN OUT VMAX VMIN FTIM SOC NEXT BACK EXIT

...

DAY 1 DAY 29 DATA

Long push to reset

(100%)

Toggle setting lockout (’A’ showing means settings adjustable)

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7.0 SET menu

The set menu contains most of the settings which control the operation of the controller.

7.1 TIME

This screen displays the time on the controller’s clock. A 24hr format is used for system time, with a resolution of 6 minutes (0.1 hours) So, for example, 14.3 is 2:18 PM.

Program Function Table (Generic Programs)

Program#: 0 1 2 3 Batt Type:

Flooded

Sealed

Flooded

Sealed

LOAD Term Functions:

No Night Light Night Light

Low Battery Disconnect

Low Battery Disconnect is enabled for Programs 0-3.

Programs 2&3 turn on the LOAD terminal at night for lighting applications.

Program Description

PROG 0: Use with liquid electrolyte lead acid

(ie. flooded) batteries. The LOAD terminal is set to turn off when the battery is low. (Also known as Low Battery Disconnect)

PROG 1: Use with sealed or gel lead acid

batteries. The LOAD terminal is set to turn off when the battery is low.

PROG 2: Use with liquid electrolyte lead acid

batteries (ie. flooded). The LOAD terminal is set to turn on all night and can be used for night lighting. It will turn off when the battery is low (Low Battery Disconnect).

PROG 3: Use with sealed gel lead acid batteries.

The LOAD terminal is set for night lighting, with low battery disconnect.

PROG 4: Enables customised adjustment of all

settings.

Installation instructions for programs 0-3 are on pages 8-9 of the User Guide.

Settings Used in Programs 0-3

When programs 0-3 are selected, the PL automatically uses the values below in its regulation. These are not visible on the screen

Set

time

Set

battery

voltage

TIME VOLT PROG REG MODE EVNT

Set

program

BATV

CHRG

LOAD

OUT

DATA

SET

Fig. 7A - The SET Menu

NOTE: Removing power to the regulator (i.e. turning it off) will reset the system time to 10.0hrs (10:00 AM).

The time must be set whenever the regulator is restarted. Incorrect system time will result in misleading history data since this is stored at midnight of each day. Generator quiet-time and time-driven event control will also be affected.

7.2 VOLT

Set VOLT to the nominal system voltage for the installation.

This setting determines the regulation and control voltage set-points for the system. For correct regulation, this setting MUST be correct.

NOTE: The controller will not be damaged if the voltage is set incorrectly but the battery will probably be damaged (under- or overcharge) if this setting is in error for more than a few days.

7.3 PROG (Adjusting Regulation Settings)

The PL comes with a number of preconfigured programs, which are set up for generic batteries. For custom installations, selecting program 4 allows the user to adjust each setting individually.

If you find you are unable to change your settings, it may be because the “lockout” setting is activated. This setting is designed to prevent unwanted tampering— please see the “Setting Lockout” information in section 6.5.

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and are not adjustable by the user. For adjustable settings, choose program 4.

The voltage settings are shown correct for 12V operation. For higher voltages, scale these up (eg. for a 24V system, multiply each voltage figure by 2.)

Settings for Program 4

If program 4 is selected, then all settings can be accessed and adjusted.

After TIME, VOLT and PROG, there are entry points for three further sub menus:

REG Allows the user to customise the regulation settings for the PL (see below for details).

MODE Allows the user to adjust other configuration options for the PL.

EVNT Settings for the event controller.

CHRG

Setting for program number

Parameter 0 1 2 3

GMOD 0

G ON (V) 11.5

GOFF (V) 13.8

GDEL (Min) 10

GEXD (Day) 30

GRUN (Hr) 1.0

LOAD

Setting for program number

Parameter 0 1 2 3

LOFF (V) 11.3

L ON (V) 12.8

LDEL (Min) 10

SET/REG

Setting for program number

Parameter 0 1 2 3

BMAX (V) 15.0 14.2 15.0 14.2

EMAX (V) 16.0 14.0 16.0 14.0

ETIM (Hr) 1.0 0 1.0 0

EFRQ (day) 45

ABSV (V) 14.0

ATIM (Hr) 2.0

FLTV (V) 13.8

HYST (V) 0.4

BRTN (V) 12.3

CHRG (A) 20

BFRQ (Day) 15

TCMP 0

SET/MODE

Setting for program number

Parameter 0 1 2 3

LSET 1 1 4 4

GSET 2 2 9 9

ESET Default or Prog 4 settings

BSET 0 0 2 2

BAT2 (V) 14.0

PWM 1

ALRM (V) 11.4

SET/EVNT

Setting for program number

Parameter 0 1 2 3

STRT 12

TIME (Hr) 0

STOP 12

TIME (Hr) 25.5

EMOD 2

TMOD 0

SET/MODE/ ESET

Default Settings

SW 1 to 5 0 (charge switch -on to charge)

SW 6 to 9 3 (load switch -off to disconnect)

SW A 5 (off when alarm active)

SW b 6 (on when event is active)

SW C 7 (off when event is active)

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7.4.1 HYST (Hysteresis Value)

When not in PWM mode, the PL controls the battery voltage by simply switching the charge current on and off. It turns off the charge current at the relevant set point for the state (Float, Boost, Equalise, Absorption), and allows the charge current to turn back on at a slightly lower voltage. The gap between the two voltages is called hysteresis.

Example:

With the PL in float mode and slow switching (i.e. not using PWM), the charge current will be turned on until the battery voltage rises to the FLTV value. Once the FLTV value has been reached, the charge current will be turned off until the battery voltage falls to FLTV – HYST (float voltage minus the hysteresis value) at which time the charge current will be turned on again until the battery reaches FLTV and the cycle begins again.

The larger the hysteresis values, the slower the rate of switching on and off will be.

NOTE: When switching a mechanical relay for regulation purposes, the HYST value may need to be increased so that the relay does not wear out quickly due to rapid switching.

BATV

CHRG

LOAD

OUT

DATA

SET

TIME VOLT PROG REG MODE EVNT

BMAX

EMAX

ETIM

EFRQ

ABSV

ATIM

FLTV

HYST

BRTN

CHRG

BFRQ

TCMP

Set max boost voltage

Set max equalisation voltage

Set equalisation time

Set # days between eq.cycles

Set absorbtion voltage

Set absorbtion time

Set float voltage

Set hysteresis

Set boost return voltage

Set charge current limit

Set max days to between boost cycles

Set temp compensation profile

Fig. 7.4A - Regulation Settings (Program 4 only)

SET/REG Submenu Summary:

Name Description Range

BMAX Maximum voltage in

boost mode

13.5-16.5V

EMAX Equalisation voltage 14.0-17.0V

ETIM Equalisation time 0-2.0 hours

EFRQ Number of days between

equalisation cycles

20-150

ABSV Absorption voltage 13.5-15.5V

ATIM Absorption time 0-4.0 hours

FLTV Float voltage 13.0-15.0V

HYST Hysteresis used when

not in PWM mode

0.1-1.0V

BRTN Voltage below which

return to Boost mode occurs

11.0-13.0V

CHRG Charge current limit 0.5-20A

BFRQ Maximum number of days

between boost cycles

1-20

TCMP Selection of temperature

compensation profile (see below 7.4.3)

0-8

7.4 REG menu (Customising Regulation Settings) [PROG=4 only]

To adjust the regulation settings, long-push on “SET”, short-push to “REG”, and long-push (see fig 7.4A).

The settings given below are for 12V systems. For other system voltages the value can be scaled from this. (eg. for a 24V system, multiply all voltages by 2.)

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The setting TCMP is used to select a temperature profile, which determines how this compensation is achieved.

The PL can automatically sense the presence of a temperature sensor if one of the autosense profiles is selected. However, if operation at temperatures below -12oC is common, it is better to use the non auto sense profile (TCMP=4-7). The auto sense will not detect sensors colder than -16oC

Fig. 7.4.3B shows the temperature compensation curves for each TCMP setting. Consult the battery manufacturer for correct compensation for the battery used.

Timers:

The HYST value is also used to start and stop the timers associated with the different regulator charging states (Boost, Equalise, and Absorption).

Example:

When the PL changes to the Absorption state, an internal timer is started to monitor how long the regulator has been in Absorption. If however the battery voltage falls lower than ABSV - HYST this timer is stopped, and starts again when the battery voltage rises above ABSV - HYST. This ensures that the regulator holds the system in the required state for the correct programmed time and doesn’t continue to the next charging stage until this time has elapsed.

NOTE: An exception to this is the Equalise State, which will terminate after 4 days if unable to complete the full specified time period.

7.4.2 Charge Current Limit

The PL has a built-in charge current limit. If the charge current exceeds the CHRG setting, the PL will reduce the duty cycle to limit the average charge current.

This allows the PL to protect itself from overheating due to excessive charge current. The maximum charge current can also be limited for small batteries where the full array current might be too much for the battery. This is useful for systems, which are marginal in winter, but have too much charge current for the battery in summer.

It can also be useful where there is an initial ageing effect in the first few months of the life of the module. For example, with amorphous modules the initial current may be more than the charge current rating of the PL. Making use of this feature, panels can be installed with the full rating calculated after the initial drop off.

7.4.3 TCMP (Temperature compensation)

(Default=0, Adjustable in Program 4 only)

A temperature sensor is available which allows the PL to adjust its regulation voltage settings to compensate for variations in battery temperature.

SET/REG/TCMP Selection Summary:

TCMP Function Example Battery

0 -5mV°C linear

auto sense (default)

General Purpose - use this if in doubt

1 gentle curve

auto sense

BP Solar Block

2 steeper curve

auto sense

Sonnenshein Dry Fit

3 limited range

curve auto sense

Absolyte battery

4 -5mV°C linear

non auto sense

General Purpose use this if in doubt

5 gentle curve

non auto sense

BP Solar Block

6 steeper curve

non auto sense

Sonnenshein Dry Fit

7 limited range

curve non auto sense

Absolyte battery

8 No temperature

sensor

(Failsafe: if short across T- T+ inputs)

Note: Without a temperature sensor fitted, the PL will display 0°C.

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Fig. 7.4.3B - Temperature compensation curves

P L T

P L T B

Battery Battery

temperature

sensor

mounting

PLT PLTB

Neoprene sponge

Fig. 7.4.3A - Attaching a Temperature Sensor to a battery

Connecting a Temperature Sensor

The temperature sensor should be connected to the T+ and T- terminals in the green terminal block (under the lid, above the top left corner of the LCD screen). The sensor wire with the stripe goes to the T– terminal and the sensor wire without the stripe goes to T+ terminal. The wires may be extended if necessary without affecting the accuracy.

Note: The PLTB (bolt-on metal lug) has no electrical connection to metal lug lug housing, so it can be connected to either the negative or positive battery terminal.

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7.5 MODE Menu (Adjusting Configuration Settings) [PROG=4 only]

LSET

GSET

ESET

BSET

BAT2

PWM

BCAP

ALRM

RSET

DFLT

BATV

CHRG

LOAD

OUT

DATA

SET

TIME VOLT PROG REG MODE EVNT

Set function of LOAD terminal

Set function of general purpose terminal (G)

Set control of external switches

Set function of B input

Set Regulation voltage for 2nd battery control

Set which terminals use Pulse width Modulation

Set amp Hour capacity of the battery (20-20,000AH)

Set voltage at which to activate alarm

Reset system (losing today’s data and time)

Reload factory default settings

Fig. 7.5A - MODE Menu

The MODE submenu contains most of the settings for the configuration of the PL other than the main regulation settings.

7.5.1 & 7.5.2 LSET & GSET

There are two output terminals on the PL (LOAD and “G”) and six logical control functions. The LSET and GSET settings define which of the six functions controls each of these output terminals.

Note that the settings described below are different from the LSET and GSET screens described in Section 2 and 3.

The six internal control functions are:

Low battery disconnect. This also controls the “LOAD” indicator at the bottom of the screen.

Run the backup generator. This also controls the “GEN” indicator at the bottom of the screen.

Charge a second battery. Indicates when the solar input can be diverted to a 2nd battery.

Battery voltage alarm output. Provides an output based on the battery voltage.

Shunt regulation. Gives an output useful for

SET/MODE Selection Summary:

Name Description Range

LSET Select the control of

the LOAD switch

0-11

GSET Select the control of

the “G” relay

0-11

ESET Select the control for

external switchblocks

see below

BSET Select the use of the

B+ sense input

0-2

BAT2 Regulation voltage for

2nd battery control

13.0-16.0V

PWM Select which terminals

use PWM (SOL, LOAD) 0-3

BCAP Amp hour capacity of

the battery bank

20-20,000Ah

ALRM Alarm voltage 10.0-18.0V

RSET Resets the controller (warm reboot).

Clears day data and time

DFLT Resets Prog 4 settings to Prog 1 settings.

Used to reset factory default settings.

regulation by dumping the input energy.

Event controller. An output which is active when a specified set of conditions occurs.

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The LSET setting allows the user to choose which function controls the electronic switch connected to the LOAD terminal. The user can also select whether that switch is on or off when the function is active. (i.e. select normally open or normally closed)

For example, if LSET is set to 9, then the load switch would turn ON if the battery voltage is lower than the alarm voltage setting (ALRM). This could be used to turn on an alarm light.

SET/MODE/LSET

# Function Terminal is:

0 Low battery

disconnect

on when function wants to disconnect battery

1 Low battery

disconnect (default)

off when function wants to disconnect battery

2 Generator

control

on when function wants to run generator

3 Generator

control

off when function wants to run generator

4 Event control on when event is on

5 Event control off when event is on

6 2nd battery

charge control

on when battery 2 should charge

7 2nd battery

charge control

off when battery 2 should charge

8 Alarm output off when battery

voltage < alarm setting

9 Alarm output on when battery

voltage < alarm setting

10 Shunt control

(Must be selected for PWM control of the LOAD- terminal)*

off when function wants to disconnect the shunt load (ON for regulation)

11 Shunt control

(PWM must not be set to 2 or 3)*

on when function wants to disconnect shunt load (OFF for regulation)

* Don’t use LSET=11 with PWM, as design does not allow inversion of PWM signal.

SET/MODE/GSET

# Function Terminal is:

0 Low battery

disconnect

on when function wants to disconnect battery

1 Low battery

disconnect

off when function wants to disconnect battery

2 Generator

control (default)

on when function wants to run generator

3 Generator

control

off when function wants to run generator

4 Event control on when event is on

5 Event control off when event is on

6 2nd battery

charge control

on when battery 2 should charge

7 2nd battery

charge control

off when battery 2 should charge

8 Alarm output off when battery voltage

< alarm setting

9 Alarm output on when battery voltage

< alarm setting

10 Shunt control** off when function wants

to disconnect shunt load (ON for regulation)

11 Shunt control** on when function wants

to disconnect shunt load (OFF for regulation)

** Note: PWM is not available on G Terminal

If LSET is set to 8, then the load switch would turn OFF when the battery voltage goes below the ALRM setting. This could be used to turn off a load to reduce the drain on the battery.

The GSET setting allows the user to choose which function controls the general purpose “G” relay, and whether it is on (closed) or off (open) when the function is active.

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will control each external switch block. This is done in the ESET sub menu. A long push on ESET brings up the first switch setting. Short pushes move to the next switch until ESET returns after switch C.

The following table shows the control options.

SET/MODE/BSET Selection Summary:

Selection Function

0 B+ input used for battery

positive voltage sensing

1 2nd battery voltage sensing

2 external input VEXT, used by

event controller

7.5.3 BSET: Configuring the B+ Sense Input

The terminal labelled B+(right most terminal of the green terminal block) is intended as a sense input for the battery positive voltage. This can be connected directly to the battery positive terminal so that the PL can read the true battery voltage. This is important if there is significant voltage drop along the wiring (including the fuse) between the BAT+ terminal on the PL and the real battery positive. (If there is significant voltage drop on the negative side, then take the

Shunt Control

The PL supports either series control, shunt control, or both at the same time. In a hybrid system, the main solar component is controlled by the SOL input and the other charge component (wind, hydro, etc) is directly connected to the battery and controlled by a dump load which diverts excess charge. The dump load is managed by the PL’s shunt control function. This can operate via the LOAD or ‘G’ terminal either directly or through a relay. These functions are configured in the LSET and GSET screens. (see section 7.5.1 and 7.5.2)

Regulating Wind / Hydro:

Shunt control is appropriate for wind generators or microhydro systems, which require a constant load on the charging source so the generator doesn’t overspeed and destroy itself. In this case the charging source must remain connected to the battery at all times.

“Shunt control” (also referred to as “diversion control”) refers to the technique of controlling the battery voltage by drawing energy from the system with a ‘dump load’, rather than disconnecting the charge source as “series control” does on the solar input.

To regulate a wind or microhydro installation with shunt control, a dedicated dump load must be available for the PL to switch across the battery. The dump load current should be larger (at the range of expected battery voltages) than the maximum charge current available from your generator.

The function of the dump load is to ‘soak up’ energy coming in which the battery cannot store in order to maintain the desired battery voltage.

7.5.3 ESET: External switch setup

The PL controller has a serial bus which allows the user to add external devices to increase the controll system’s capability. One such device is an electronic switch. This can be used to increase the charge current being regulated or increase the load current being controlled by the load disconnect function.

The user needs to select which internal function

SET/MODE/ESET Selection Summary:

Selection Function

0 Charge control (normal/slow)

On when PL wants to charge

1 Charge control (shunt/slow)

Off when PL wants to charge

2 Load disconnect (inverse)

On when load should be off

3 Load disconnect (normal)

Off when load should be off

4 Alarm (normal)

On when battery<ALRM voltage

5 Alarm (inverse)

Off when battery<ALRM voltage

6 Event (normal)

On when the event is active

7 Event (inverse)

Off when the event is active

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

 

BOO ST

Fuse/Breakers

Battery

–

B+ Sense wire (Connect to Battery Negative Terminal)

Fuse/ Breakers

Connect close to battery terminals

Solar Panel(s)

B- B- B- S+ B+ L+

(NOTE: Low Current 'B Sense' wires can be significantly smaller than other wires.)

Fig. 7.5.3A - Battery Sense Input







BOO ST

Battery

–

B- B- B- S+ B+ L+

Push Button

Light

Fig. 7.5.3B - Push button connection

BAT- terminal directly to the battery negative via a fuse. The fuse need only be rated for the PL current, say 100mA. Take the negative side of the charge current from the array to the battery separately via it’s own fuse. The idea is that the array current is not passing through the same wire as the PL negative supply current). See figure 7.5.3A

If the B+ input is not being used for this, then it can be used for sensing the voltage on a second battery being charged or for providing a voltage input for the event controller (VEXT).

‘Push Button’ Switch Input

To use the B+ sense input as a switch event input, wire a switch (or other voltage free contact closure device) between the B+ terminal (green terminal block) and the Bat+ terminal (and set BSET = 2). See Figure 7.5.3B

This is an example of using a push button switch to turn on a light - see section 7.6 Event controller example 2 for setting details.

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B sense input

Relay

2nd

Solar

Use LOAD or ‘G’ output to switch relay (Wiring for ’G’ output shown)

Solar Array

(Relay shown in non-energised state)

1st

Solar







BOOS T

B- B- B- S+ B+ L+

Battery 1

(Primary)

Battery 2

(Secondary)

Fig. 7.5.4A - Second Battery Control

7.5.4 BAT2 - Second battery control

On many afternoons, there is power available from the solar panels but it is wasted because the batteries are already full by then. This power could be used to charge a second or reserve battery bank. The PL has a separate single stage controller for a 2nd battery built into it. This allows the second battery to charge if the PL has reached the float state and the voltage on the 2nd battery is below the setting in the BAT2 screen.

The second battery control function uses a relay to switch the solar array positive from the primary battery to the secondary battery.

NOTE: Second battery control is not suitable for use in positive ground systems since it uses the B+ sense input and requires the battery positive terminals to be separated (i.e not both connected to the chassis) Use a positive ground controller in this case.

With the negatives of the two batteries joined together, the PL can read the voltage on the second battery from the B+ sense input. An external switching device such as a changeover relay will be required to switch the negative of the solar panel(s) from the SOL terminal of the PL to the positive terminal on the second battery (see fig 7.5.4A).

Use either the Load terminal or ‘G’ relay for switching the changeover relay (the ‘G’ relay max current is only 300mA, but this should be enough

to drive most relays). The following settings will also need to be configured:

PROG=4 allows changing LSET, GSET,

BSET etc

LSET=6 or GSET=6

LSET if using load terminal for relay, GSET if using the ‘G’ relay to switch the changeover relay

BSET=1 ‘B+’ input used for 2nd battery

control

The ‘B+’ sense input is wired to the positive terminal of the second battery and allows voltage monitoring of the second battery voltage. This allows the regulator to perform basic single stage regulation of the second battery by switching the relay on or off to connect/disconnect the charge source. A second regulator is NOT required.

The changeover relay will need to meet the following minimum specifications:

Correct coil voltage to match the system voltage, ie. able to handle the maximum battery voltage.

Output contacts rated for DC current.

Output contacts rated to handle the maximum current that the connected panels can output.

Note: It is suggested that customers leave some panels permanently connected to the regulator SOL+ input (1st solar) and switch all the other panels (2nd solar) across with the relay . This leaves a regulated ‘maintenance’ charge available for the

•

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In the fast switching mode, the PL uses pulse width modulation (PWM) at 250Hz. It is recommended that PWM control be used unless there is good reason not to, as it provides a smoother control and faster charging.

PWM may generate some audio or radio frequency interference. If you experience noise on electronic equipment (for example AM radio), you could try selecting SET/MODE/PWM = 0 (slow switching only, option available when PROG=4). If this does not fix the problem, it’s unlikely that the noise is generated by the PL controller.

The radio frequency interference from the PL has been tested in PWM mode and found to be very low. It is at least 15dB below the domestic limit for European and Australian EMI compliance standards.

NOTE: More care must be taken at higher system voltages (particularly 48V) because the inductance of the wiring to the photovoltaic panels can cause some ‘ringing’ on turn-off. Keep wiring as

primary battery, and can minimise the amount of switching required by the relay (which switches over each time the primary battery bank voltage falls below FLTV - HYST). The maximum relay switching rate is one cycle per 30 seconds. A DC output solid state relay is a good choice for this application

This setup may not be the best use of available charge current. Consider if it would be better to increase the size of the primary battery bank.

7.5.5 PWM and Slow Switching

When the PL is trying to keep the battery voltage constant, it does this by turning the charge current on or off as required. It can do this quickly or slowly.

PWM (fast switching):

SET/MODE/PWM: [PROG= 4 Only]

Selection Function

0 No PWM used

1 PWM on SOL terminal only

2 PWM on LOAD terminal only

3 PWM on both

short as possible and panel cable pairs together (cable tie). On long wiring runs at higher voltages, some damping may be necessary and possibly some external clamping of transients. With highly inductive wiring, the transients may be large enough to damage the FET switch. Consult the factory if further information is required.

LOAD terminal PWM switching: For PWM control to be available on the LOAD terminal, LSET must be set for Function 10 (Shunt Control). DO NOT set LSET to

Function 11 (Inverted Shunt Control) if using PWM on load terminal—see the LSET table.

PWM should only be enabled on the LOAD terminal (PWM = 2 or 3) if the PL is using the LOAD terminal to directly switch a dump load (no relay).

An exception to this is when the LOAD terminal is driving a solid state ‘electronic’ relay (nonmechanical), as these can usually switch at the PWM speed (250 Hz).

NOTE: PWM is not available on the G relay.

Slow Switching (non PWM):

In slow switching (non PWM) mode, the PL controls the battery voltage by slowly switching the charge current on and off. It turns the charge current OFF at the voltage set point for the relevant charge state, and turns the charge current back ON at a slightly lower voltage.

The gap between these two voltages is called hysteresis and is adjustable (HYST). The larger the hysteresis value, the slower the rate of switching on and off. HINT: Increase the Hysteresis value if using shunt control with a mechanical relay so the relay switches less often.

In the slow switching mode, the regulator limits the maximum switching speed to 0.25 seconds between changes. This virtually eliminates any audio or radio frequency interference.

7.5.6 BCAP

BCAP sets the effective Amp-hour capacity of the battery being charged by the PL. This is used

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by the State of Charge data screen. Long push on BCAP to set this value. Set the battery capacity actually expected as discussed in Section 6.4 (SOC).

BCAP’s range is 20Ah-20,000Ah. Short pushes will increment BCAP by 20Ah until it reaches 1000 Ah. At this point, the increment increases to 100Ah and the display changes to thousands

- i.e. 1000 is displayed as 1.0, and 1100 as 1.1. When the display reaches 20,000Ah (shown as

20.0), it will cycle back to 20Ah (shown as 20). It’s important to notice the difference. If it is intended to set 20,000Ah, be careful not to set 20 Ah instead. The two appear one after the other on the PL display during setting. The only visible difference is the decimal point to show 20,000 Ah.

7.5.7 ALRM

Long-push here to set the alarm voltage. If the battery voltage falls below the alarm voltage, the PL will activate its internal Alarm function. If the LSET / GSET settings have been configured appropriately, this can be used to enable an alarm light (or other type of alarm) connected to the LOAD or ‘G’ terminal. There is no audible alarm built into the PL. The PL can send a signal

or power to an external alarm of some kind. The reverse function could be used to turn off a low priority load when the battery voltage is getting low.

System R1 Value

12V 1K,1/4W,5%

24V 2K2,1/2W,5%

48V 4K7,1W,5%

(Higher wattage resistors may be used)

R1 values are calculated to give adequate LED brightness at low battery voltage, but not burnout at high battery voltages (eg. in case output function changed by mistake).

Settings:

SET / PROG=4

SET / MODE / GSET=9 (on when battery voltage < alarm setting)

SET / MODE / ALRM=11.4V

(for example. Set as required.)

7.5.8 RSET (Reset)

A long-push on RSET will reset the PL’s microcontroller (it’s brain). This has the same effect as disconnecting the power to the controller except that it can be done without removing a wire. It is a ‘warm reboot’.

Reset has the effect of clearing the day’s Performance Data and setting the clock to 10:00 am.

Note that you will need to re-enter the current time on the PL’s internal clock, but your other settings and history will be retained.

7.5.8 DFLT (Set Defaults)

A long-push on DFLT will cause the settings for Program 4 to be reset to the settings for Program 1. This provides a way to return the program 4 settings to the factory settings.

Example - Battery Low Alarm Output

Red LED Indicator

Resistor (R1)



  

BOO ST

B- B- B- S+ B+ L+

Fig. 7.5.7A - Alarm Wiring

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Step 2 - Set LSET, GSET or ESET

It is necessary to tell the PL which output switch will be controlled by the Event Controller. For the LOAD terminal this is done using the LSET setting. For the G relay use the GSET setting. Also, the event control can be assigned to one or more of the external switch blocks connected to the bus by using the ESET settings. These settings are described in Section 7.5.

Step 3 - Set the STRT condition.

The PL must be told what signifies the start of the event. Move to the EVNT menu, as shown in Figure 7.6A. A long-push on EVNT will move to the STRT setting. STRT uses the following table to determine what will start the event:

After setting the STRT value, a short-push will move you to the setting, which goes with that STRT value. For example, if you set STRT to “3”, you will see SOLV. Whenever the solar panel voltage drops below the value you set in SOLV, the “event” start if the other conditions permit.

STRT

(Setting)

STOP

(Setting)

EMOD

TMOD

(Setting)

EOFF / EON

BATV

CHRG

LOAD

OUT

DATA

SET

TIME VOLT PROG REG MODE EVNT

Set what determines start of Event

Set value which goes with STRT

Set what stops Event

Set value which goes with STOP

Set second condition for Event

Set third condition for Event

Set value which goes with TMOD

View current state of Event Controller

Fig. 7.6A - Event Control Menu [PROG = 4 only]

7.6 EVNT Menu (Event Control)

The event controller allows something to happen when a set of conditions is met. There are many applications for this feature, such as:

Turning on a light at night

Using ‘waste’ energy pumping water in the afternoon if the PL is in the float state

Sensor operated timed lighting at night

Turning on sprinklers for an hour if it’s over a certain temperature

Using the Event Controller

Step 1 - Select PROG 4

In Programs 0-3 the event controller is set up to do a night light function. This function is available on the load terminal in programs 2 &3 and on an external switch. For users who wish to use the event controller in a different way, Program 4 must be selected.

•

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If the start condition is to be ignored, then select STRT=0 so that the start condition is always active.

SET/EVNT/STRT Selection Summary

STRT Event starts when Value

to set

0 Always starts -

1 Time > setting (0.0-23.9) TIME

2 Solar panel voltage

(open circuit) > setting #

SOLV

3 Solar panel voltage

(open circuit) < setting #

SOLV

4 External voltage

VEXT * > setting

VEXT

5 External voltage

VEXT * < setting

VEXT

6 PB** is on and time > setting TIME

7 PB** is off and time > setting TIME

8 Repeat start at 10 min intervals

if time > setting

TIME

9 Repeat start at 30 min intervals

if time > setting

TIME

10 Repeat start at 1hr intervals if

time > setting

TIME

11 Repeat start at 2hr intervals if

time > setting

TIME

12 Battery voltage > setting VBAT

13 Battery voltage < setting VBAT

14 Repeat start at a set rate

(0-240 min)

RATE

15 Repeat start at a set rate

(0.0-24.0h)

RATE

#Note: After up to 1 min delay if the solar charge switch has not turned off.

* Note: The user can select where VEXT is measured. If BSET is set to 2, then VEXT is the voltage measured by the B+ sense input (relative to BAT+ in the negative direction). The maximum VEXT measureable this way is 27V. If BSET is not 2, then VEXT can be measured by a bus accessory,

**Note: “PB” means a push-button switch. If you wish to use this option, you can wire a switch or other contact closure device between the B+ sense terminal (green terminal block) and the BAT+ terminal, and select BSET = 2.

Step 4

Select a STOP setting in this table to tell the PL what signifies the end of the “event”.

SET/EVNT/STOP Selection Summary

STOP Event stops when Value

to set

0 Never stops -

1 Time > setting (0.0-25.2) TIME

2 Solar panel open circuit voltage

> setting #

SOLV

3 Solar panel open circuit voltage

< setting #

SOLV

4 External voltage VEXT *

> setting

VEXT

5 External voltage VEXT *

< setting

VEXT

6 PB** on and time > setting TIME

7 PB** off and time > setting TIME

8 Repeat stop at 1 min intervals if

time > setting

TIME

9 Repeat stop at 3 min intervals if

time > setting

TIME

10 Repeat stop at 6 min intervals if

time > setting

TIME

11 Repeat stop at 12 min intervals

if time > setting

TIME

12 Battery voltage > setting VBAT

13 Battery voltage < setting VBAT

14 Stop after a set run time

(0-240min)

RUN

15 Stop after a set run time

(0.0-24.0h)

RUN

#Note: After up to 1 min delay.

*Note: “VEXT” has the same meanings as in the STRT table.

**Note: “PB” has the same meanings as in the STRT table.

After setting the STOP value, a short-push will move you to the setting, which goes with that STOP value.

For example, if you set STOP to “1”, you will see TIME. Once started, the “event” will then

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continue until the time reaches the time you specify in the TIME setting. One use of this combination of STRT and STOP could be to turn a light on between dusk and 11pm.

If the stop condition is to be ignored, select STOP=0 so that the stop condition is never active.

NOTE: an event will not start, if the stop condition is active when the start condition becomes active. In other words, stop has priority over start.

Step 5

Next, short-pushes bring the EMOD setting and then the TMOD setting. These settings can be used to set more conditions, which must be true for the event to be active.

For example, the EMOD setting could be used to ensure the light only turns on if the PL is in the Float state (EMOD=1).

If additional conditions are not needed, they can be set to zero and they will be disregarded (always active).

SET/EVNT/EMOD Selection Summary

EMOD EMOD is active when: LBD

0 Always active

(EMOD condition is irrelevant)

1 PL is in Float mode Y

2 It’s night Y

3 It’s day Y

4 The external D input is active Y

5 PL is in Float and it’s night Y

6 PL is in Float and it’s day Y

7 PL in Float & external D active Y

8 Always active N

9 PL is in Float mode N

10 It’s night N

11 It’s day N

12 The external D input is active N

13 PL is in Float and it’s night N

14 PL is in Float and it’s day N

15 PL in Float & external D active N

For settings 0 to 7, the low battery disconnect (LBD) function will override the EMOD conditon and make EMOD inactive if the load should be disconnected. This makes it possible to disable an event if the battery voltage is too low.

Settings 8-15 are the same as 0-7 but without the LBD overide.

SET/EVNT/TMOD Selection Summary

The TMOD setting provides an extra adjustable test condition

TMOD TMOD is active when Value

to set

0 Always active

(TMOD irrelevant)

None

1 temperature > setting TEMP

2 temperature < setting TEMP

3 battery voltage > setting VBAT

4 battery voltage < setting VBAT

5 *VEXT > setting VEXT

6 *VEXT < setting VEXT

7 Time > setting TIME

8 Time < setting TIME

* Note: VEXT depends on the setting of BSET.

If BSET=2, then VEXT is the voltage on the B+ sense terminal. (This voltage is relative to the BAT+ terminal in the negative direction [max 27V]).

If BSET is less than 2, then VEXT is an external voltage read by a bus accessory.

After setting the TMOD value, a short-push will move to the associated setting, as for STRT and STOP.

Step 6

Finally, a short-push displays a screen, which shows the current state of each of the conditions, and whether the “event” is currently active.

If the “event” is inactive, then to turn it on all three conditions (STRT, EMOD and TMOD) must become active (i.e. show as “1”).

When the “event“ is active, if the STOP condition takes place or the TMOD or EMOD condition goes inactive (ie “0“), then the event will turn off.

If the display shows “E ON” then the “event”

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is currently active. If it shows “EOFF” then the “event” is currently not active, but will become active when all of the preset conditions are met.

The numeric figure shows the state of each of these conditions.

The first digit shows the status of the STRT and STOP conditions. If the event is off (EOFF), the first digit shows the state of the STRT condition (0 = inactive, 1 = active). If the event is on (E ON) the first digit shows the state of the STOP condition. In the example, above, this figure will be “0” during the day (i.e. STRT condition is inactive), then “1” at dusk when the solar panel voltage drops to the pre-set SOLV value. If the battery was fully charged, the event will start, the display will change to “E ON” and the first digit will flick back to “0” to show that the STOP condition is inactive. If the battery was not fully charged, the event will not start, the display will stay on “EOFF”, and the first digit will remain on “1” until either the PL enters the Float state (when the event will start), or 11pm comes (when it will flick to 0 until next evening).

The second digit shows the state of the EMOD condition. In the example above, this digit will be “1” when the battery is in the Float state, and “0” if it is in the Boost, Equalise or Absorption states.

The third digit shows the state of the TMOD condition. In the example above, TMOD was not used, and this digit will always be “1”.

Whether EMOD is on (1) or off (0)

if EOFF: Whether STRT is on (1) or off (0) if E ON: Whether STOP is on (1) or off (0)

Whether TMOD is on (1) or off (0)

Whether event is on (E ON) or off (EOFF)

EOFF

001

Fig. 7.7A - Event State

Examples:

1. To turn a light on all night

STRT STOP EMOD TMOD

0 0 2 0

The first two conditions have the effect of making STRT and STOP irrelevant. The STRT condition will always be on, and the STOP condition will never happen.

In practice, the EMOD condition will determine whether the event is on or off. Because it is set to 2, it will be on at night. If a light is wired to the LOAD terminal and LSET=4, then the light will turn on at night. (The light would also turn off if the battery voltage drops low enough for the LBD function to operate)

2. Pushing a button turns a light on at night for 10 minutes:

STRT TIME STOP RUN EMOD TMOD

6 0 14 10 2 0

If a momentary ON push-button is wired up between B+sense and BAT+, the STRT condition will turn on with the push-button input (the time will always be greater than 0). It will stop after 10 minutes due to the STOP and RUN settings. EMOD=2 makes sure that this will only happen at night - during the day, pressing the push-button will have no effect. Note: The user also needs to set BSET=2 & LSET or GSET=4

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3. Pump water if battery is fully charged until tank is full (i.e. switch in tank turns off):

STRT STOP

TIME

EMOD TMOD

0 6 0 1 0

The STRT condition is always true. The STOP condition becomes true when a float switch in the tank (wired between the PL’s BAT+ and B+ sense terminals) switches off (open), i.e. the tank is full.

To add the ‘fully charged condition’, EMOD is set to 1. This requires the controller to be in the float conditon (i.e. almost fully charged) before the EMOD conditon will become active.

When the PL enters Float state, EMOD will become active and, as STRT is always true and TMOD is always true, the pumping will start if the tank is not full. .

Note: BSET=2, LSET or GSET=4

4. Water garden for 5 minutes every 100 min from 2pm until nightfall

STRT RATE STOP RUN EMOD TMOD TIME

14 100 14 5 3 7 14.0

The STRT condition is true every 100 minutes, i.e. repeated start at 100 minute intervals. The STOP condition causes the event to run for only 5 minutes after each event start. This cycle will continue while it is daytime (EMOD = 3) and it is after 2pm (TMOD = 7, TIME = 14.0).

Note: LSET or GSET = 4

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A.0 Appendices

A.1 Accessories

There are accessories, which can enhance the usefulness of the PL controller.

External Battery Temperature Sensor (XLT or XLTB)

The XLT is a plastic-cased unit for direct attachment to the battery wall. The XLTB has a bolt-on lug for attaching to the battery terminal (either terminal).

The unit connects to the T+ and T- inputs on the green plug in terminal block under the wiring cover. See Section 7.4.12 for further details about this unit.

XLM, XLS2, XLI

The following accessories plug into the serial port socket which is under the wiring cover.

Remote Control (XLM)

The PL can be accessed remotely with the remote control. All of the functions work in the same way as on the actual controller. Includes built-in audible alarm and display backlighting.

External Shunt Adaptor (XLS)

Up to four external shunts can be added to the PL to allow it to measure larger currents than it is capable of measuring directly. The shunt adaptor measures the current in a shunt (eg SH200), converts it to digital information and sends that information back to the PL. The connection to the shunt is DC isolated from the PL so the shunt can be placed in any part of the circuit. Currents up to +/-250A can be read in

0.1A steps. See the XLS instruction sheet for more

information.

Computer/Modem Serial Interface (XLI)

An RS232 level serial interface is available which allows the PL to communicate with a computer or be remote accessed via a modem. This is a quick way to load settings into the PL or extract performance data. All of the data is remotely accessible, and all settings can be adjusted. Software is available for IBM compatibles to make this easy. Data can then be loaded into a spreadsheet or other applications.

A.2 Specifications

Nominal system voltages 12,24,32,36,48 V

Maximum voltage BAT+ to BAT-

100 V

Max short term voltage BAT+ to BAT-

120 V

Maximum voltage SOL+ to BAT-

100 V

Max. voltage LOAD to BAT+ 70 V

Max. voltage between the “G” relay terminals

90 V

Max. voltage B+ sense to BAT+ +/-30 V

Max. continuous charge current (SOL+)

20 A

Max. continuous load current (LOAD+)

20 A

Max. short term* load current

(*a few mins)

30 A

Max “G” relay current 300 mA

Battery Temp sensor range -20 to

+70

°C

Max. storage temperature 70 °C

Supply Current (PL only, 12V) 10 mA

Supply Current (PL only, 60V) 16 mA

Supply Current max (with acc.) 30 mA

Meter Accuracy <+/-2% +/-1 display digit

Max wire entry size: 16mm2 (6 AWG)

Wire size, Green Terminal Block

= 0.14 - 0.15mm2 = 26-16 AWG

A.3 Block Diagram

This PL Controller is designed for common negative installations (i.e. switches solar and load on the positive side).

It has a reverse blocking mosfet switch between the SOL+ terminal and the BAT+ terminal and a mosfet switch between the LOAD+ terminal and the BAT+ terminal. There is also a low current bi-directional mosfet switch between the ‘G’ terminals.

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A.4 Thermal derating

The current rating of the PL must be reduced at high ambient temperatures or the display will darken until it is unreadable. The currents indicate what can be done at the same time. Because the limit is due to heating, there are many combinations of charge and load current which will produce the same heat level. This table shows the limits of some combinations.

Air temperature around the PL (°C)

Charge Current Max

Load Current Max

PL20 PL40 PL60 PL20 PL40 PL60

40°C 20 A 40A 60A 20 A 7A 30A

44 20 40 60 0 0 30

18 37 10

13 20

48 35 0 60 30

50 18 32 60 0 0 30

5 20

13 10

55 13 28 55 0 0 18

0 50 20 30

A.6 Mechanical Information

Material:

Case: Polycarbonate Heatsink: Anodised Aluminium

Weight (in box): 500g

Unit Dimensions:

PL20: 100 x 109 x 40mm

(Height x Width x Depth)

Scale = 1 : 1.5

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SOLAR BATTERY LOAD

DISPLAY

TEMPERATURE SENSOR (T+,T-)

SERIAL PORT



�

SOL

BAT

LOAD





 





‘G’ RELAY

BATTERY SENSE (B+ SENSE)

SHUNT SHUNT

REVERSE BLOCKING FET SWITCH

FET SWITCH

B- B- B- S+ B+ L+

BATTERY-

SOLAR+

BATTERY+

LOAD+

‘G’ Terminals

Temperature Sensor T-

Temperature Sensor T+

B+ Sense

BATTERY-

‘G’ Terminals

Serial Bus

Block diagram and terminal layout

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PL20N Reference Manual







BO OS T

B- B- B- S+ B+ L+

















Page 38

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PL20N Reference Manual

NOTES

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Rev 1.0 25.07.07PL20N Reference Manual

Section:

Programs 0-3 Menu System

(Programs with fixed settings)

Thin arrow = short push Thick arrow = long push

(Explained in User Guide p6)

Set

time

Set

battery

voltage

TIME VOLT PROG BCAP

VMAX VMIN TEMP SOLV HIST

FTIM

DAY1 IN OUT VMAX VMIN FTIM SOC NEXT BACK EXIT

DAY 2 IN OUT VMAX VMIN

VMIN

FTIM

SOC

BACK

EXIT

DAY2

DAY99 DATA

DATA

EXIT

ININOUT

OUT

VMAX

DAY 3

DAY99

DAY 4

DAY 1

SOC

BATV

Set

program

CHRG

LOAD

OUT

DATA

SET

Toggle function status on/off

GRUN

GDAY

CINT External

GSET

Set length of generator exercise

View/change # of days since last exercise (or run time if generator running)

LINT

External

LSET

Toggle low battery disconnect status on/off

INT External

Clear

INT External

Clear

Toggle setting lockout ('A' showing means settings adjustable)

set to 100%

DATA

Note: GSET will not toggle if clock is between 9pm -> 9am (Quiet time)

DAY1 DAY98

Set

battery

capacity

BOST EQUL ABSB FLOT

set to

current BATV

Page 41

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PL20N Reference Manual

BOST EQUL ABSB FLOT

Program 4 Menu System

(For adjustable settings)

Set

time

Set battery voltage

TIME VOLT PROG REG MODE EVNT

VMAX VMIN TEMP SOLV HIST

BMAX

EMAX

ETIM

EFRQ

ABSV

ATIM

FLTV

HYST

BRTN

Set max boost voltage

Set max equalisation voltage

Set equalisation time

Set # days between eq.cycles

Set absorbtion voltage

Set absorbtion time

Set float voltage

Set hysteresis

Set boost return voltage

CHRG Set charge current limit

BFRQ Set max days to between boost cycles

TCMP Set temp compensation profile

FTIM

DAY1 IN OUT VMAX VMIN FTIM SOC NEXT BACK EXIT

DAY 2 IN OUT VMAX VMIN

VMIN

FTIM

SOC

BACK

EXIT

DAY2

DAY99 DATA

DATA

EXIT

ININOUT

OUT

VMAX

DAY 3

DAY99

DAY 4

DAY 1

SOC

BATV

Set

program

CHRG

LOAD

OUT

DATA

SET

Toggle function status on/off

Set generator control mode

G ON

GOFF

GDEL

GEXD

GRUN GDAY

G ON

GOFF

GDEL

GEXD

GRUN

GDAY

SOC%

1 or 5

G OFF

GEXD

GRUN

GDAY

SOC%

G ON

CINT External

GSET

GMOD

2 or 6

0 or 4

GRUN

Set V/SOC% to start generator

Set SOC% to stop generator Set V to stop generator

Set delay before on/off change

State of Charge (SOC) Long push to reset (100%) Set days between generator exercises

Set length of generator exercise

View/change # of days since last exercise (or run time if generator running)

LINT

External

LSET

LOFF

L ON

LDEL

Toggle low battery disconnect status on/off

Set voltage at which load disconnects

Set voltage at which load reconnects

Set delay before switching

INT External

Clear

INT External

Clear

Toggle setting lockout ('A' showing means settings adjustable)

LSET Set function of LOAD terminal

GSET Set function of general purpose terminal (G)

BSET Set function of B- input

BAT2 Set Regulation voltage for 2nd battery control

PWM

Set which terminals use Pulse width Modulation

BCAP

Set amp Hour capacity of the battery

ALRM

Set voltage at which to activate alarm

RSET

Reset system (losing today's data and time)

STRT

(Setting)

STOP

(Setting)

EMOD

TMOD

(Setting)

EOFF / EON

Set what determines start of Event

Set value which goes with STRT

Set what stops Event

Set value which goes with STOP

Set second condition for Event

Set third condition for Event

Set value which goes with TMOD

View current state of Event Controller

set to 100%

DATA

Note: GSET will not toggle if clock is between 9pm -> 9am (Quiet time) unless GMOD is set to 4, 5 or 6 (no-Quiet time)

Thin arrow = short push Thick arrow = long push

(Explained in User Guide p6)

DAY1 DAY98

Section:

ESET

Select which internal function controls an external switch*

DFLT

Return settings to factory defaults

set to

current BATV

* ESET Submenu not shown for clarity

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NOTES

Plasmatronics PL20, PL40, PL60 Reference Manual

Specifications and Main Features

Frequently Asked Questions

User Manual