PL User Guide Rev U4e
Contents
1. Customised setup Choosing this program will require you to set anumber of additional parameters See page 18 for more information d When the program shown is correct long push to set it 4 Set the Battery Capacity a Short push to move from PROG to BC AP b Long push once and the battery capacity will start flashing c Short push to choose the correct battery capacity for your system in Ampere 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 PL User Guide PL User Guide 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 SO C 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 is needed so that the PL can include the inverter in its calculations How much energy have I collected today The top level2. 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 load has used today What voltage did the battery reach VMAX shows today s maximum voltage since midnight VMIN shows today s minimum voltage Both are in the DATA sub menu What time did the battery finish charging today The FTIM screen in the DATA sub menu shows the time the PL finished bulk charging and entered the float state see page 14 Are components working correctly An optional temperature sensor can be connected to your PL to improve regulation If this sensor is installed the battery temperature is shown on the TEMP screen in the DATA sub menu To test your solar array SO LV in the DATA menu shows the open circuit voltage the solar array is generating PL User Guide PL User Guide Retrieving historical data In addition to storing today s performance data the PL keeps Quick Summary information about the last 30 days of operation IN The amount of energy collected in Amp hours Historical performance information can be accessed from the OUT The amount of energy used in Amp hours DATA screen see diagram below After along push on DATA VMAX maximum battery voltage since midnight short push until you see HIST A long push on HIST will put VMIN minimum battery voltage since midnight you in history mode where you can cycle through each day s FTIM
3. time of day the regulator entered the Float state data N ote that the day numbers go backwards i e DAY 1 see page 14 means yesterday and DAY 30 is 30 days ago SOC Percentage estimate of the state of charge of the battery based on the amp hours A very rough fuel Thin arrow short push Thick arrow long push gauge TEMP temperature being sensed by the external sce VMAX gt VMIN gt FTIM gt SOC gt TEMP SOLV HIST temperature sensor if attached SO LV solar panel voltage open circuit NB the PL stops charging the battery while displaying this screen entry point for history data Y LOAD DAY 1 gt IN gt OUT gt VMAX gt VMIN gt FTIM gt SOC gt NEXT gt BACK gt EX nai DE ZE ZE 2 2 2E E DA de DATA DAY 2 IN gt OUT gt VMAX VMIN gt FTIM gt SOC gt NEXT gt BACK gt EX Mu Vv vv st WY WY OY YW ows om of At midnight IN OUT VMAX VMIN FTIM and SOC are DAY 3 IN gt OUT gt VMAX gt VMIN FTIM gt SOC gt NEXT BACK gt EX stored in the history data and reset or iol 1 1 L L y y y 4 4 4 4 4 4 4 DAY4 DAY2 DATA VMAX and VMIN respond very slowly to changes in battery DAY 30 IN gt OUT VMAX gt VMIN gt FTIM gt SOC gt NEXT gt BACK gt EX voltage This allows them to ignore short term voltage fluctuations PL User Guide PL User Guide The Battery Charging Process When charging your battery the PL moves automatically The diagram b
4. Advanced Solar Charge Controller User Guide Read this before installing Plasmatronics Pty Ltd ABN 98 073 758 497 www plasmatronics com au Rev U4e 03 02 PL User Guide PL User Guide Connection for temperature sensor generator and battery Wiring instructions 4 sensors under the cover Expansion Socket H LCD under the cover Display _ Button Using the Menus see reference manual x instructions for instructions a are on page 6 Choosing your settings Monitoring your system Mounting Screw holes Flange a use these mount e for mounting Where to set up your PL vertically Pe LOAD for best Make sure you set up your PL pertormance A Wertically where air can circulate s around it Batter EI Batter Load F i Ey Array ry h Yhn a dry environment out of direct Positive N eaative N egative N egative light Terminal tenni Terminal Terminal sunlight y innide Screw wires into these terminals tightly Away from flammable gases or liquids as described on page 4 Away from spiders wasps or other Warning The PL regulator is for DC current ONLY insects which might make nests in it PL User Guide PL User Guide Wiring instructions Wires should be connected tightlyas follows a Connect the fuse on the positive terminal of the battery to the BAT terminal on your PL See diagram b Connect the positive terminal of the solar p
5. anel to the fuse on the positive terminal of the battery c Connect the fuse on the negative terminal of the battery to the BAT 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 SOL terminal of the PL MORE INFORMATION on wiring the PL60 is on page 19 The PL has aLow Battery Disconnect feature see page 16 which disconnects equipment powered by your battery known as a load if the voltage gets too low To use this feature e Connect the fuse at the positive terminal of your battery to the positive terminal of your load f Connect the negative terminal of your load to the LOAD terminal of your PL g Some equipment can damage the PL when it switches off To prevent this connect the diode supplied between battery and LOAD as shown in the wiring diagram Australian Standards recommend that you connect an appropriate fuse to each terminal of the battery Fuses are not supplied with the PL SOLAR Supplied diode stripe to Max Load Currents bat Warning N ever connect inverter or battery to LOAD LOAD terminal AN SF FAS FF AT ae eee MEN ELIAS Fuse PL20 20A PL40 7A PL60 30A BATTERY PL User Guide PL User Guide Using the Menus Moving around You can move around the menu system and change settings using the button on the front of t
6. elow shows how the voltage of the battery varies through the following charging sequence throughout the charging process Boost phase In this phase all available charge is used to The regulation settings shown in the diagram BMAX ETIM charge the battery as quickly as possible W hen the battery etc can all be set individually in Program 4 This means the PL is charging in the Boost phase the Boost indicator appears can be adjusted to regulate well even in unusual installations on the PL s screen For more information about doing this see page 18 Absorption phase The battery is nearly full To avoid excess In most cases the pre set values provided by choosing gassing the charge current is now adjusted to keep the Programs 0 1 2 or 3 will be ensure good regulation without a battery voltage constant complex setup process Float phase The battery is fully charged so the PL now c monitors the battery and keeps it full If the battery voltage The Battery Gade drops below a pre set point the battery will move back to QIME EMAX the Boost phase automatically A crei To increase battery life the PL will occasionally 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 BATTERY VOL The PL moves through these phases automatically but it is also possible to change the phase manually A long
7. follow the procedure below to ensure that your PL will regulate correctly 1 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 N ote 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 shown is correct If you reach 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 c Short push until the voltage is correct for your battery If you reach 48V it will cycle back to 12V 4 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 Batteries with Low Battery Disconnect option see page 16 PROG 1 Gel batteries with Low Battery Disconnect option PROG 2 Liquid Electrolyte batteries with Light Controller option see page 17 PROG 3 Gel batteries with Light Controller option PROG 4
8. he PL There are seven top level menu items in the PL s menu system BATV CHRG LOAD etc see diagram opposite Each menu item provides access to a sub menu and some of these sub menus lead again to further sub menus A short push tells the PL to advance 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 A long push selects moving into a sub menu or allowing you to change settings To do along 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 already changing a setting see page 8 and when you see the word EXIT you re in History mode see page 11 Thin arrow short push Thick arrow long push N a BATV gt CHRG C T CE T Generator Control LOAD gt LINT gt LEXT p Low Battery Disconnect Yao N Regulator State T gt EXT Clear Clear OUT gt INT gt EXT Clear Clear DATA V Roe SEIN TIMA SO C TEMP 50 eet History Data SeT gt TIME VOLT PROG BCAP Set Set Set Set PL User Guide PL User Guide Choosing your settings You must
9. on power to the P s LOAD terminal If you have connected lights to the PL s 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 9 You should then wire your lights to the LOAD terminal as described in parts e and f on page 4 N ote that if the battery s voltage falls below a pre set level the Low Battery Disconnect function will protect the battery by switching off the lights even if it is dark Optional Accessories The following optional accessories are also available for the PL Ygattery temperature sensor PLT and PLTB Plug in shunt adapters which with shunts allow the PL to incorporate an inverter or backup generator in its calculations and to measure currents of up to 250A PLS2 Ynterface for remote control via a computer and a modem PLI PL User Guide PL User Guide Other Features The PL has a number of features which are not described in this User Guide These include Yuy customisable regulation settings via Program 4 ontrolling equipment such as sprinklers pumps lights etc ontrolling a backup generator harging a second battery iggering an alarm when the battery is low mperature compensation isabling tampering via a lockout setting configuring the use of the PL s terminals unt regulation and pulse width modulation options For information on how to cus
10. 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 ATIM BRIN BOOST EQUALISATIABSO RPTIO NFLO AT BO OST PL User Guide PL User Guide Low Battery Disconnect O ption Low BatteryD isconnect is a feature of the PL which helps avoid battery damage by preventing the load from excessively draining the battery You do not have to use this feature the PL will still regulate effectively without it Low Battery Disconnect works by turning the load off when the voltage falls below a pre set point for a period of time This feature 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 regulator as described on page 4 and you should also ensure that you have chosen a program where the Low Battery Disconnect feature is activated see page 9 Note NEVER connect batteries or inverters to the LOAD terminal of the PL They will cause heavy current flow which will damage the regulator Light Controller O ption The Light C ontroller is an additional optional function of the PL It can be used to switch lights on during darkness When the voltage from the solar array drops the Light C ontroller function will switch
11. tomise your regulation setup and use these additional features consult the Reference Manual This is available from your dealer or from the Plasmatronics web site at www plasmatronics com au More information on the optional accessories can also Be found on the website PL60 Connections o pes Poog Be y 2 ZZ B 5 as Bee f g 574 rege g ai SOzZ ic E 5 gange F 5 Oorraa 9 oie OC Dyer ele JOJ D 0 lt Z 0 TEE oz zzp z ra O Cogs a 3S v vsz Les ao naseg Bos 5s N iv p go 155 er a of on Py Eg HEeee se gugeds wn 3 a5 pease Z Jr oe SoES Fg p p EY O20 R oO BEABDSS amp y x Soot FA Ss lt O 53 3 2b o 6 a2 Efugnvg 5 D JEE SSE yg 2 TERTE 9 RBeeEnaae A 0 2orve va peeege gy pe See Se FFEE s3Y
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