DL-300 Charge Controller User Manual
Contents
1. M axing Edge DL 300 Charge Controller User Manual Tel 44 0 845 6520396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Carine Edge Introduction Please read this manual thoroughly before attempting to assemble install or operate your LE DL 300 Charge Controller This will assure optimum performance and safety The LE DL 300 Series Dump Controller and Load is an integrated solution designed to prevent 12 or 24 Volt batteries from overcharging It is designed to be used with small wind systems operating a LE 300 turbine Compact and easy to install the LE DL 300 was developed especially for the LE 300 turbine It incorporates a 300 Watt resistor heater and controller board in a stout powder coated steel enclosure Operation amp Specification The LE DL 300 dump load controller operates like an electrical overflow for your batteries As the LE 300 turbine charges the batteries the State of Charge SOC and battery voltage will rise As the batteries become fully charged and are no longer able to accept any further electrical energy the battery voltage will rise At this point the dump load controller begins to bleed power into the dump load This energy is then dissipated as heat into the surrounding environment More or less power is diverted to the dump load according to how much is being supplied to the battery from the turbine The LE DL 300 Features PWM Pulse Width Modulation for highest charg2. d conduit trunking Cable strain relief Prevent mechanical strain on all cables Cable ties or cable glands are a good way to prevent mechanical strain on the cables Fuses The LE DL 300 controller should be protected with a suitably rated slow blow DC fuse or DC circuit breaker Please refer to the table below for the correct rating The fuse or breaker should be positioned between the DL300 and batteries on the positive cable Nominal Voltage DC Fuse DC Circuit Breaker Rating 12V 30 Amp 24V 15 Amp Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 4 of 7 axing Edge Electrical Connections of DL300 Controller DL 300 Voltage Set Points Whilst operating the DL 300 does a multi stage charge based on time and the bulk and float voltages 12V Setpoints Mode Flooded Sealed Bulk 14 6 14 3 Float 13 4 13 4 Protect 16 0 15 0 24V Setpoints Mode Flooded Sealed Bulk 29 2 28 6 Float 26 8 26 8 Protect 32 0 30 0 Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 5 of 7 Carine Edge LED Indicators e Standby Mode when first powered up o both LEDs blink simultaneously every 7 seconds e Charging Mode o bulk green blink long delay green blink o absorb green blink short delay green blink o float green solid o dumping red solid whe
3. er supplied should be applied to pins labelled 2 2 when the LE DL 300 is to be used with flooded batteries When the LE DL 300 is to be used with Gel batteries no jumper should be applied to pins 2 2 In any circumstance no jumper should be applied to pins 2 1 Use the correct voltage controller A 12V DL300 controller should only be used on a 12V battery system A 24V DL300 controller should only be used on a 24V battery system Do not interchange Follow the appropriate electrical code The electrical wiring of your LE 300 turbine and associated electrical systems must be done in accordance with national and local electrical codes and regulations Do not connect the turbine or batteries during the installation Ensure that the turbine is not running or connected to the batteries during the installation or wiring process Connect the output cables of the turbine together to prevent the rotor from starting up Galvanic corrosion of electrical joints Try to avoid connections between dissimilar metals For example connecting copper and aluminium together will result in galvanic corrosion of the connection This will increase the electrical resistance of the connection wasting energy and reduce the mechanical integrity of the joint Where possible use a fluxed solder to make electrical joints Protect the cables The power transmission cables must be protected from mechanical damage and fatigue Run the cables through an approve
4. ing performance without flicker Selectable three stage charging or over voltage protection mode Selectable for sealed or flooded batteries using jumpers Power 12 Volt version DL300 12 Recommend fuse or circuit breaker 30 Amps Integrated load resistor 300 Watt wire wound Quiescent current when not load dumping 2 6mA 12 Volts Power 24 Volt version DL300 24 Recommend fuse or circuit breaker 15 Amps Integrated load resistor 300 Watt wire wound Quiescent current when not load dumping 3 0mA 24 Volts Connections 10 32 brass screws for V and V Two 1 2 3 4 concentric NPT knockouts and two 1 2 NPT knockouts Mounting Mounts to vertical concrete metal drywall or other non flammable surface Uses four 10 screws Body sits 19 mm out from wall Enclosure suitable for indoor mounting Weight and Dimensions Dimensions 88 mm wide 95 mm tall 470 mm long 3 375 x 3 75 x 18 5 in Weight 1 94 Kg 4 28 pounds Shipping Dimensions 102 mm wide 108 mm high 508 mm long 4 0 x 4 25 x 20 in Shipping Weight 2 15 Kg 4 75 pounds Materials Enclosure 18 gauge mild steel powder coated black Circuit board FR 4 1 6 mm 0 062 in double sided plated through holes solder mask silk screen gold plating Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 2 of 7 axing Edge Safety Precautions Safety must always be your primary concern during the assemb
5. ly installation and operation of your LE 300 turbine and DL300 charge controller Always be aware of the risks involved with mechanical and electrical installation work If in doubt about any issue regarding your turbine system please seek further assistance before proceeding Mechanical Safety Hazards Whilst installing the DL300 charge controller or when performing routine inspection or maintenance always stop the turbine by activating the stop switch Electrical Safety Hazards The LE 300 generates rectified DC voltage and the LE DL 300 controller also operates at these voltages Even at these low voltages there are inherent risks Caution should always be used when connecting an LE 300 turbine or LE DL 300 controller to the electrical system Ensure that you have followed the cable sizing guidelines to ensure that the correct size of cable has been selected If a cable of insufficient cross sectional area is used at any point in the electrical system heat will build up in the cables causing a potential fire hazard A properly sized fuse or circuit breaker should be used in the cables connected to the battery This will stop the risk of short circuit currents Batteries used in renewable energy systems can deliver a serious amount of current A short circuit in the battery circuit can lead to hundreds of Amps flowing through the battery cables This will cause a heat build up and ultimately an electrical fire Batteries are also susceptible t
6. n duty cycle gt 0 Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 6 of 7 Contact Us Leading Edge Turbines Ltd Skyrrid Farm Pontrilas Hereford HR2 OBW UK UK 0 845 652 0396 Outside UK 44 1981 241 668 info leturbines com www leturbines com Wl caine Edge Your Local Distributor
7. o explode when shorted Always use insulated electrical tools when working on the battery s electrical connections Batteries are very heavy Do not attempt to move batteries by yourself Always use manual handling tools and an assistant Always keep lead acid batteries the correct way up Do not allow the acidic electrolyte to spill or come into contact with your skin Always follow the manufacturer s safety instructions when handling lead acid batteries Please use common sense when installing and operating your turbine and LE DL 300 Charge Controller Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 3 of 7 K Edge Electrical Installation Please refer to electrical schematic for appropriate generic wiring diagrams In a battery charging renewable energy system there may be different ways of wiring small wind turbines photovoltaic panels charge controllers and batteries together This type of system will often expand organically but the following guidelines should be followed Location The LE DL 300 controller should be mounted in an adequately ventilated area which is not exposed to direct moisture or spray The dump load elements become hot during normal operation and should not be covered or blocked Gel or Flooded Batteries An electrical jumper needs to be configured in order to make the controller more suitable for use with Flooded or Gel batteries A jump
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