Controller Operation
Contents
1. disconnecting the 4 pin connector from the battery and solar panels will connect or disconnect the power to the controller G 2 Motor Power Connect Disconnect The power to the motor can be connected or disconnected by either connecting or disconnecting the power to the controller as indicated in G1 or by connecting disconnecting the 2 pin connector on the controller to the motor2. Controller Operation BR1100 Solar Powered Chemical Injection Pump PUMP CONTROLLER USER MANUAL A USER INTERFACE A 1 SWITCH Defines S Accesses menu system and cycles between stroke time stroke frequency and duty cycle UP Increments stroke time and stroke frequency values DOWN Decrements stroke time and stroke frequency values START Starts motor ON OFF cycle mode PRIME Starts motor Prime mode STOP Terminates motor ON OFF cycle or Prime mode or exits from menu system A 2 LED State Defines STROKE ON indicates stroke time is selected while in menu system FREQ ON indicates stroke frequency is selected while in menu system DUTY ON indicates duty cycle is selected while in menu system RUN ON indicates motor is running in motor ON OFF cycle or Prime mode OFF otherwise PRIME ON indicates motor is running in Prime mode CHARGE ON indicates battery is charged blinking at 1 sec interval indicates battery is charging and OFF indicates solar panel is not present or there is insufficient light for charging A 3 SEVEN SEGMENT DISPLAY Strings oF Idle state system is not in motor ON OFF cycle or Prime mode or within menu system on Motor ON OFF cycle mode Pr Motor Prime mode Fl Motor short circuit fault code F2 Low battery fault code B MOTOR MODES The motor can run in either of two modes motor ON OFF cycle or Prime mode In motor ON OFF cycle mode the motor and the RUN LED stays ON for a time according to stroke time and sta
3. UP DOWN switches have no effect Menu system functions normally if the system is in Prime mode Pressing the S switch turns ON the STROKE LED and displays the stroke time The stroke time is the length of time that the motor turns on for during each cycle Pressing UP or DOWN switch while in stroke time sub menu allows the stroke time to be changed from 0 1 to 9 9 seconds Pressing the S switch again will turn ON the FREQ LED and display the stroke frequency The stroke frequency is the number of cycles per minute that occur Pressing UP or DN switch while in stroke frequency sub menu allows the stroke frequency to be changed from 0 1 to 9 9 cycles per minute Depending on the stroke time selected there is a upper limit to the maximum stroke frequency that can be selected Pressing the S switch again will turn ON the DUTY LED and display the calculated duty cycle calculated from the selected stroke time and stroke frequency values Duty cycle values in the 10 0 to 99 9 range are displayed as 10 to 99 values in the 0 1 to 9 9 range are displayed as 0 1 to 9 9 while values less than 0 1 are displayed as 0 0 Pressing the S switch again takes the user back to the stroke time sub menu Useful Formulas Duty Cycle Stroke Frequency 100 60 Time between Start Cycles in seconds 60 frequency Stroke 0 6 Duty Cycle Frequency Frequency 0 6 Duty Cycle Stroke The menu system is exited under the following conditions 1 No switc
4. h has been pressed for 5 secs menu time out occurs and system exits to last state 2 STOP switch is pressed system exits to idle state 3 START switch is pressed system exits to motor ON OFF cycle mode 4 PRIME switch is pressed system exits to motor Prime mode Selected stroke time and stroke frequency values are written to EEPROM before a menu exit D SLEEP MODE If no switch has been pressed for 30 seconds the seven segment display amp LEDs are blanked and system enters into sleep mode to conserve power If motor ON OFF cycle mode or Prime mode had been selected before sleep selected mode continues to run in sleep mode Exiting out of sleep mode is accomplished by pressing any switch The system will wake up and display the last state before sleep mode oF for idle state on for motor ON OFF cycle mode or Pr for Prime mode E FAULT CONDITIONS E 1 Motor short circuit While in motor ON OFF cycle mode and motor is running if a short occurs across the motor windings the system shuts off the drive to the motor and displays fault condition message F1 During subsequent ON OFF cycles the system will keep on trying to turn on the motor If the fault condition goes away the fault condition message is replaced by motor ON OFF cycle mode message on While in Prime mode if a short occurs across the motor windings the system shuts off the drive to the motor and displays fault condition message F1 If the PRIME switch is
5. pressed again the system will try to turn on the motor again If the fault condition goes away within 60 secs the fault condition message is replaced by Prime mode message Pr E 2 Low battery The system displays F2 if the battery voltage falls below 11 5V System operation continues to run normally under low battery fault condition Low battery fault condition has lower priority than motor short circuit fault condition F BATTERY CHARGING F 1 Float Charging The system monitors the battery voltage at 1 sec intervals and performs temperature compensated float charging assuming a solar panel is present and there is sufficient light The CHARGE LED blinks at 1 sec intervals when battery is being charged and turns steady ON when battery reaches float voltage at the given temperature F 2 Battery Equalization Temperature compensated battery equalization is performed automatically every 7 days until battery voltage reaches equalization voltage or system has been in equalization mode for 24 hours whichever is earlier During equalization mode the RHS decimal point of 7 segment display is turned ON for on oF Pr F1 or F2 message displays Holding any button pressed when system is powered up displays EE and forces system into equalization mode G POWER CONNECT DISCONNECT G 1 Controller Power Connect Disconnect The power to the controller can only be connected or disconnected by the power source to the controller Connecting
6. ys OFF for a time according to stroke frequency and stroke time This cycle is repeated until the STOP switch is pressed In Prime mode the motor and the RUN LED stays ON until 60 seconds have elapsed or the STOP switch is pressed Motor ON OFF cycle mode is initiated by pressing the START switch while Prime mode is initiated by pressing the PRIME switch On the fly mode changes are permitted between motor ON OFF cycle and Prime modes without first hitting the STOP switch The 7 segment display shows on when motor ON OFF cycle mode is selected and Pr when Prime mode is selected If either mode is terminated by using the STOP switch or when Prime mode times out after 60 seconds the display shows oF indicating system is now in idle state The system remembers if it was in motor ON OFF cycle mode and powers up in ON OFF mode if system was in ON OFF mode when power was interrupted C MENU SYSTEM The menu system user interface consisting of the S UP amp DOWN switches 7 segment display and STROKE FREQ amp DUTY indicator LEDs allows the user to change the stroke time and stroke frequency for motor ON OFF cycle mode Duty cycle cannot be changed directly in the menu system and the UP DOWN switches have no effect Menu system changes are allowed only if the system is NOT in motor ON OFF cycle mode Pressing the menu switch while in motor ON OFF cycle mode allows the user to view the stroke time stroke frequency and duty cycle values but the
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