CC-PPL User`s Manual - Systellar Innovations
Contents
1. INNOVATIONS CC PPL User s Manual Introduction Congratulations You are the proud owner of one of the best PWM charge controllers available in India Please read this manual carefully before installing and operating the charge controller Advanced PWM charge controller series CC PPL comes in two models PPL_1224 20 and PPL_1224 40 Both these models can work on 12V or 24V battery banks automatic battery voltage selection and can handle maximum 20 40 Amps charging current respectively Product description SOLAR CHARGE CONTROLLER CC PPL 1224 I LT L CHARGING Green J CHARGED Green I 1_____ niGHT Mob Rea BATTERY STATUS e i E Sa Ess LED to indicate aim tellar battery charging a Innovations status a E A he Q SOLAR PANEL BATTERY LOAD a g e TEF BATTERY i i i j jj ii _ SEYRE z z oR PV ve i f ay N Load ve PV ve Battery ve Battery ve Load ve Side View Power Battery Saver Temp Jumper Socket Sensor setting PS Batt ojijo i Ea 2 battery type selection 8 jumpers Power Saver Night For connecting Light Relay external Battery Power Saver Connector temperature setting jumpers Optional Accessory 1 sensor Optional INNOVATIONS The following battery types can be selected using jumper settings 1 SMF Sealed Maintenance Free 2 Flooded Flat plate 3 Flooded Tubular A four sta2. ff the mains supply to the inverter and thus save electricity Note that in this condition the load connected from the inverter will be driven by the battery while the battery is being charged by the solar panels Technical specifications Maximum charging current Technology Battery bank voltage Auto select Maximum solar panel voltage PWM duty cycle range Idle current from battery typical Battery deep discharge protection load shut down voltage Load shut down recovery Battery voltage Max Load current Other Features INNOVATIONS CC PPL 1224 20 CC PPL 1224 40 20 Amp 40 Amp Zero voltage drop Pulse Width Modulation 12 24V 50 Volts 0 100 10 ma typical 10 8 21 6V 12 25 24 5 Volts 20 Amp 1 When load is On battery is connected to load output Load output is designed for maximum 20A DC Current In case this current is exceeded the load is Shut Off To restart load reduce the load So that load current does not exceed 20 Amp and change the position of JMP3 or JMP4 temporarily to reset Load Overload shutoff condition 2 In case battery voltage drops below 10 8 21 6 V the load is shut off It will automatically reset when battery voltage rises above 12 25 V 24 5 V or if JMP3 or JMP4 position is changed Company Contact details Systellar Innovations Shankar Chowk Delhi Road Meerut 250002 Ph 0121 2400394 Email info systellar in www systellar in
3. g 4 mm sq copper cable Keep cable length around 2 Metres Voltage drop in the cable has been adjusted in the software with these cable dimensions Observe correct polarity while connecting wires from battery and Solar panels If the wrong polarity is connected the Batt connection fault LED will start glowing Correct the polarity before proceeding further 4 As soon as the battery cables are connected the Charge Controller will start working and its Red green LED indicator will start glowing blinking 5 Check open circuit voltage of the solar panels For optimum results open circuit voltage of the solar panels should be matched with the battery bank voltage For 12V battery bank use 30 or 36 cell solar panel Voc 19V or 21V For 24V battery bank use 60 or 72 cell solar panel Voc 37V or 43V For CC PPL maximum solar panel voltage should be less than 50 volts This means that maximum two 12V solar panels V 19 21V can be connected in series Any number of such series strings may be connected in parallel to increase the power of the solar panels INNOVATIONS If 24V solar panels are used V 37 43V then these panels should not be connected in series These panels should only be connected in parallel to each other 6 Connect solar panel to the charge controller in correct polarity Once connections are made if it is day time the battery charging will start after about 15 seconds LED indicator CC PPL ha
4. ge battery charging algorithm best suited for the selected battery type is implemented which can charge battery with precise current and voltage levels to achieve fast battery charging yet ensuring long battery life They provide the following advanced features 1 Power Saver relay drive This feature along with an optional Power saver relay box provides a means to cut off mains supply to the inverter during the day when the battery is fully charged This helps in saving electricity coming from the electricity board The mains supply is reconnected 2 hours before sunset or when battery voltage becomes less than a programmable voltage in the range of 11 2 to 11 8 Volts This voltage can be set using two jumpers 2 D C Load output There is a D C output same voltages as the battery bank voltage which is capable of driving a 20 Amp load Normally this output is always ON It is turned off if the battery voltage drops below 11 0Volts to prevent deep discharge of the battery 3 Temperature sensor input This feature along with an optional temperature sensor probe adjusts battery charging voltages based on the temperature of the battery This ensures optimum battery charging and longer battery life Installing the Charge Controller 1 Install the Charge Controller indoors near the battery bank at chest height This will make it easy to make connections and make any changes in the jumper settings 2 For 20A model connect the battery bank usin
5. in Off Voltage 11 2V Off Voltage 11 4V Off Voltage 11 6V Off Voltage 11 8V Note For 24V battery bank multiply the setting voltage by 2 Settings indicated for 12V Optional Accessories 1 Battery Temperature sensor TO EXTERNAL BATTERY TEMPERATURE STICK THIS SENSOR SENSOR CONNECTOR OF CC_MPPT TO BATTERY External Battery Temperature Sensor Battery temperature sensor is supplied as an optional accessory Paste the temperature sensor on the battery side using adhesive tape Insert the 4 pin RJ11 connector at the end of the temperature sensor cable in the socket provided on the right side of the charge controller Note that if temperature sensor is not inserted in the connector in CC_PPL the battery charging voltages suitable at 25 deg C are used automatically INNOVATIONS 2 Power Saver accessory W Power Saver Accessory MAINS SUPPLY 230V im ete e eoe POWER SAVER NIGHT LIGHT SWITCH RELAY BOX TO POWER SAVER NIGHT LIGHT SWITCH RELAY CONNECTOR OF CC_MPPT CONNECT INVERTER MAINS SUPPLY HERE Power Saver Connection Diagram Connect the plug of power saver box in Mains power socket Connect inverter mains cord to the socket provided on the Power saver box Connect the 2 pin PV connector to the Power saver socket on the right side of the charge controller Now when it is day and the battery voltage is more than 13 5 V 27 V the relay will turn on This will cut o
6. s a bi colour Red green LED which gives a variety of indications about the functioning of CC PPL Condition Indication 1 System un calibrated system fault Red 30 blinks 100 msec On 100 msec Off 2 Battery discharged Red Three 50 msec blinks at 2 seconds interval 3 Load shutoff due to Low Battery voltage or Red Two 50 msec blinks at 2 seconds interval Load current exceeding 20 Amp 4 Battery voltage too high system fault Red Solid On Unlikely fault 5 Dusk dawn verification Green Two 50 msec blinks at 2 seconds interval 6 Battery fully charged Green Solid On 7 During DAY Charging current lt 1 Amp Green One 50 msec blink at 2 seconds interval 8 During DAY Charging current gt 1 Amp Green 500 msec On 500 msec Off 9 During NIGHT Red One 50 msec blink s at 2 seconds interval Note that the above is prioritized list of indications i e when a higher priority indication is there any lower priority indication will not be given during that period Setting programmable parameters using jumpers There are two sets of 2 jumpers each on the right side of the CC PPL Their settings are as under 1 Battery type selection Jmp1 and Jmp2 Batt Jumper Battery Type Selection Jumper setting Jumper setting Jumper setting SMF type battery Tubular type battery Flat Flooded type battery INNOVATIONS 2 Power saver turn off voltage setting Jmp3 and Jmp4 PS Jumper Power saver switch off voltage sett
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