PL60 / PL80 User Guide
Contents
1. Please read this Warning This controller is for DC current only It is NOT an MPPT device There is no voltage conversion Suitable array maximum power point MPP ranges are 12V sys 16 19V 24V sys 32 38V 48V sys 64 76V The load current rating is 30A for the PL60 and 40A for the PL80 The G terminal is implemented as a solid state relay voltage free contacts with 0 3A 100V max rating There are two small screws in the sides of the lid These screws are essential for trans port Transporting the unit without these screws in place will result in damage which will not be covered under warranty Keep these screws Connect the catch diode supplied across load terminals stripe to LOAD see page 4 g PL60 PL80 User Guide Wiring Instructions Wires should be connected tightly as fol lows a Connect the fuse on the positive terminal of the battery to the BATT POS terminal on your PL See dia gram b Connect the positive terminal of the solar panel to the SOL POS termi nal of PL c Connect the fuse on the negative terminal of the battery to the BAT TERY NEG terminal of the PL The display panel of the PL should then start up d Connect the negative terminal of the solar panel to the SOLAR NEG terminal of the PL Note if using this PL in a motorhome or vehicle please see our website for suggested wiring diagrams WARNING Never connect an in verter or battery2. NEXT gt BACK gt EXIT PL60 PL80 User Guide 5 The battery charging process When charging your battery the PL moves automatically through the following charg ing sequence Boost phase In this phase all available charge is used to charge the battery as quickly as possible When the battery is charging in the Boost phase the Boost indicator appears on the PLs screen Absorption phase The battery is nearly full To avoid excess gassing the charge current is now adjusted to keep the bat tery voltage constant Float phase The battery is fully charged so the PL now monitors the battery and keeps it full If the battery voltage drops below a pre set point the battery will move back to the Boost phase automati cally To increase battery life the PL will oc casionally move into an additional phase called the Equalisation phase This phase levels the charge between the different cells inside the battery by overcharging the battery for a short period The PL moves through these phases auto matically but it is also possible to change the phase manually A long push on the BATV menu will show the current charging phase Subsequent long pushes will move the PL into the next phase in the cycle The diagram below shows how the voltage of the battery varies throughout the charging process The battery charging settings shown in the diagram BMAX ETIM etc can all be set individually in Program 4 This means the
3. PL can be adjusted to charge well even in unusual installations For more information about doing this see page In most cases the pre set values provided by choosing Programs 0 1 2 or 3 will be ensure good charge control without a com plex setup process The Battery Charge Cycle TIME EMAX _ _ __ gt re n u x w a O lt ey BMAX _ z ABSV Wi E ETIM a gt FLTV ATIM BRTN BOOST EQUALISATION ABSORPTION FLOAT BOOST 10 PL60 PL80 User Guide Low battery disconnect Low Battery Disconnect is a feature of the PL which helps avoid battery damage by preventing the load from excessively drain ing the battery You do not have to use this feature the PL will still charge the battery properly Low Battery Disconnect works by turning the load off when the voltage falls below a pre set point for a period of time This fea ture is designed not to trigger if the battery voltage drops for just a few moments for example because a motor has just been turned on Once the battery has recharged to a safe level the load will automatically switch on again To use Low Battery Disconnect you need to connect your load to the PL as described on page 4 In Programs 0 3 Low Battery Disconnect is always enabled Note NEVER connect batteries or inverters to the LOAD terminal of the PL They will cause heavy current flow which will damage the PL Light controller option The Light Contro
4. for your battery 4 Set the Battery Capacity a Short push to move from PROG to BCAP b Long push once and the battery capac ity will start flashing c Short push to choose the correct bat tery capacity for your system in Am pere hours Ah Large settings display in thousands eg 1600 Ah shows as 1 6 If you are unsure check your battery manual or consult your battery supplier d Long push to keep the chosen value Monitoring your system The PL s advanced monitoring functions provide you with unparallelled information about your system Here are some of the questions your PL can answer How full is the battery The voltage level of your battery is an approximate measure of how full it is and is shown on the top level BATV screen Alternatively SOC in the DATA sub menu long push on DATA then three short pushes uses the amp hour data to provide an educated guess of the state of charge Warning SOC will be useless if the PL is not measuring all the charge and discharge from the battery For example if an inverter is connected directly to the battery an external shunt with a PLS2 Shunt Adapter is needed so that the PL can include the inverter in its calculations How much energy have I collected today The top level IN screen shows how many Amp hours have been collected today How much energy have I used today The top level OUT screen shows how many Amp hours the lo
5. shown is correct If you go past 23 9 it will cycle back to 0 0 midnight e When the time shown is correct long push to set it 2 Set the System Voltage a After setting the time short push to move from TIME to VOLT Long push and the voltage will start flashing b Short push until the voltage is correct for your battery If you pass 48V it will cycle back to 12V c When the battery voltage is correct long push to set it 3 Set your program The PL comes with a number of pre set programs to make configuration easy for most installations a After setting the battery voltage short push to move from VOLT to PROG b Long push once and the program number will start flashing c Short push to set your program PROG 0 Liquid Electrolyte Flooded bat teries with Low Battery Disconnect PROG Gel AGM Sealed batteries with Low Battery Disconnect PROG 2 Liquid Electrolyte Flooded batteries with Low Battery Disconnect and Light Controller option see pg 10 PROG 3 Gel AGM Sealed batteries with Low Battery Disconnect and Light Controller option PROG 4 Customised setup Choosing this program will require you to set a number of additional parameters See page for more information d When the program shown is correct long push to set it Programs 0 3 are generic programs for dif ferent battery types Consult your battery supplier for the settings recommended
6. to the LOAD terminal The PL has a Low Battery Disconnect feature see page 10 which disconnects equipment powered by your battery known as a load if the battery voltage gets too low To use this feature e Connect the positive terminal of your load to the LOAD POS terminal on the PL f Connect the negative terminal of your load to the LOAD NEG terminal of your PL g Some equipment can damage the PL when a load disconnect occurs To prevent this connect the diode supplied between battery and LOAD as shown in the wiring diagram Australian Standards recommend that you con nect an appropriate fuse to each terminal of the battery Fuses are not supplied with the PL LOAD ea TAF AF AAS O SOLAR BATTERY Supplied diode stripe to bat Fuse PL60 Max 30A PL80 Max 40A Using the Menus Moving around You can move around the menu system and change settings using the button on the front of the PL There are seven top level menu items in the P s menu system BATV CHRG LOAD etc see diagram below Each menu item provides access to a sub menu and some of these sub menus lead again to further sub menus A short push advances the PL to the next menu or setting To do a short push press on the button on the front of the PL and release it immediately Noar BATV gt Regulator State i PL60 PL80 User Guide 5 A long push selects to m
7. Rev U6 1 01072014 ee PL60 PL80 Advanced PWM Solar Charge Controller User Guide Read this before installing 2 PL60 PL80 User Guide LCD Display Screw holes _ use these for mounting 255 Mounting Flange mount vertically for best performance Solar Charge Controller 12 48V 60A Charge 30A Load Expansion Socket under the cover see reference manual for instructions n PLASMATRONICS v N1271 Button instructions are on page 5 Connection for temperature sensor generator and battery The G Terminals are a pair of voltage free contacts When ACTIVE they are connected together When INACTIVE they are not connected together CONNECTIONS WZS SOLAR BATTERY BATT SOL CABLE NEG NEG POS POS G CONTACT 0 3A MAX G CONTACT 0 3A MAX TEMP SENSOR TEMP SENSOR B SENSE BATTERY SENSE Screws on side of the lid must be in place during transport Secure wires to these terminals tightly sensors under the cover PL60 PL80 User Guide a Wiring Instructions Using the Menus Choosing your settings Monitoring your system Where to set up your PL Make sure you set up your PL Vertically where air can circulate around it In adry environment out of direct sunlight e Away from flammable gases or liquids and e Away from spiders wasps or other insects which might make nests in it IMPORTANT
8. ad has used today What voltage did the battery reach VMAX shows today s maximum volt age since midnight VMIN shows today s minimum voltage Both are in the DATA sub menu PL60 PL80 User Guide 7 Are components working correctly An optional temperature sensor can be con nected to your PL to improve the battery charging accuracy If this sensor is installed the battery temperature is shown on the TEMP screen in the DATA sub menu To test your solar array SOLV in the DATA menu shows the open circuit voltage the solar array is generating The LCD Screen Extra system information can be obtained from words that appear along the bottom of the LCD screen BOOST The PL is in the BOOST phase of its charge cycle LOAD The PL has turned off the load output due to low battery voltage if the low battery disconnect function is enabled GEN The PL has turned on the G output to acti vate a generator if this function is enabled 5 PL60 PL80 User Guide Retrieving historical data In addition to storing today s performance data the PL keeps information about the last 30 days of operation Historical performance information can be accessed from the DATA screen see diagram below After a long push on DATA short push until you see HIST A long push on HIST will put you in history mode where you can cycle through each day s data Note that the day numbers go backwards i e DAY means yester
9. day and DAY 30 is 30 days ago Quick Summary IN The amount of energy collected in Amp hours OUT The amount of energy used in Amp hours VMAX maximum battery voltage since midnight VMIN minimum battery voltage since mid night FTIM time of day the PL entered the Float state see page 9 SOC Percentage estimate of the state of charge of the battery based on the amp hours A very rough fuel gauge TEMP temperature being sensed by the external temperature sensor if at tached SOLV solar panel voltage open circuit NB the PL stops charging the bat tery while displaying this screen HIST entry point for history data At midnight IN OUT VMAX VMIN FTIM and SOC are stored in the history data and reset VMAX and VMIN respond very slowly to changes in battery voltage This allows them to ignore short term voltage fluctua tions Thin arrow short push Thick arrow long push BATV v CHRG M LOAD M VMAX gt VMIN gt FTIM gt SOC gt TEMP gt SOLV HIST DAYI gt IN gt OUT gt VMAX gt VMIN gt FTIM gt SOC gt NEXT gt BACK gt EXIT r Ae eo A a a v DATA SET DAY2 gt IN gt OUT gt VMAX gt VMIN gt FTIM gt SOC gt NEXT gt BACK gt EXIT E e VY E E AA DAY3 gt IN gt OUT gt VMAX gt VMIN gt FTIM gt SOC gt NEXT gt BACK gt EXIT IO LL E LI t 4 l 4 DAY4 DAY2 DATA DAY30 gt IN gt OUT gt VMAX gt VMIN gt FTIM gt SOC gt
10. ery Triggering an alarm when the battery is low Temperature compensation Disabling tampering via a lockout set ting PL60 PL80 User Guide 0 Reconfiguring the use of the PLs output your PL please consult the Reference terminals Manual This is available from your dealer Shunt regulation and pulse width modu or from the our web site at lation options http www plasmatronics com au The Reference manual More information on the optional acces For information on how to use the features sories can also be found on the website above and how to customise the setup of Specifications Maximum solar Voc tor a 8V yem fo v Maximum solar voc tora 2V syren fo PV Maximum voltage between the G relay terminals 75 Maximum continuous T T E Maximum continuous charge current GOL for PLB 80 O JA Maximum continuous lad current LOAD for PL6O 30S Maximum continuous lad current LOAD for Leo 40S Maximum short term lead current lt 5 minutes for PLD 40S Maximum G relay contact current Mary OOOO oa Basiea e E T T WARNING Your PL can be damaged by incorrect installation Please read the installation instructions in your User Guide thoroughly before installing your PL Also please note Excessive load current or a short circuit can cause damage We recommend fitting a fuse or circuit breaker of an appropriate size to suit your actual load The fuse rating slow blow should not be more than 30A f
11. ller is an additional op tional function of the PL It can be used to automatically switch lights on during dark ness When the voltage from the solar array drops the Light Controller function will switch on power to the PLs LOAD termi nal If you have connected lights to the PLs LOAD terminal the PL will switch on the lights at dusk and switch them off at dawn To use the Light Controller option choose a PL program which enables this function as described on page 6 You should then wire your lights to the LOAD terminal as described in parts e and f on page 4 Note that if the battery s voltage falls below a pre set level the Low Battery Disconnect function will protect the bat tery by switching off the lights even if it is dark Optional accessories The following optional accessories are also available for the PL Battery temperature sensor PLT and PLTB Plug in shunt adapter PLS2 which with shunts allows the PL to incorpo rate an inverter or backup generator in its calculations and to measure currents of up to 250A Interface for remote control via a com puter and a modem PLI Remote Display PLM Other features The PL has a number of features which are not described in this User Guide These include Fully customisable regulation settings via Program 4 Controlling equipment such as sprin klers pumps lights etc Controlling a backup generator Charging a second batt
12. or a PL60 or 40A for a PL80 Although the PL has some protection against brief load short circuits an accidental short circuit of a few seconds can damage the PL If wires touch Charge it can Load Controller Fuse will damage PL aa protect PL l A Plasmatronics Pty Ltd ABN 98 073 758 497 http www plasmatronics com au Rev U6 1 01072014
13. ove into a sub menu or to allow you to change set tings To do a long push press the button holding it down until the menu changes about one second Getting back Wherever you are in the menu system a series of short pushes will bring you back to the top level menus without changing any settings There are two exceptions when a number is flashing you are al ready changing a setting see page 6 and when you see the word EXIT you re in History mode see page 8 CHRG gt CINT CEXT S gt Generator Control _ poe N gt INT gt ExT Clear Clear a OUT gt INT EXT Clear Clear LOAD gt LINT gt LEXT gt Low Battery Disconnect Thin arrow short push Thick arrow long push a lt DATA w VMAX VMIN FTIM SOC TEMP SOLV HIST ae 4 4 Set Set Set m SET gt TIME VOLT PROG BCAP History Data 4 Set G PL60 PL80 User Guide Choosing your settings You must follow the procedure below to ensure that your PL will charge the battery correctly Set the Time a Short push until the display shows SET b Long push once and the display will show TIME c Long push again and the time will start flashing Note that the time is displayed in hours and tenths of hours For example 6 5 means 6 30am and 13 1 means 1 06pm d Short push until the time
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