PL20N User Manual
Contents
1. If you have connected lights to the load terminals they will switch on at dusk and switch off at dawn The solar panel voltage is used to sense the light level If the battery voltage drops too low the low battery disconnect function overrides the light controller and turns the lights off To use the Light Controller option choose a program which enables this function as described on page 11 20 Dingo D4040P User Guide Further information This controller is capable of much more than what is described in this user manual For information on how to customise your regulation setup and set up larger systems as well as the many additional features consult the Reference Manual This is available from your dealer or can be downloaded from our website www plasmatronics com au Accessories These accessories can enhance the usefulness of your controller External Battery Temperature Sensor DT or DTB The DT is plastic cased unit for direct attachment to the battery wall The DTB has a bolt on lug for attaching to the battery terminal either terminal It connects to the T and T inputs on the green plug in terminal block under the wiring cover See Section 7 4 3 of the reference manual for details The following accessories plug into the accessory port socket RJ 2 External Shunt Adaptor DSA Up to four external shunts can be added to the controller to allow it to measure larger currents than it is capable of measur2. then it is OK elf the alarm led flashes quickly then it is not OK Check the polarity and test again There must be some light on the solar panels for this test to work If OK connect to the Solar negative terminal d Connect the negative wire from DC load circuit to the load negative terminal and connect the positive wire from the load to the load positve terminal Test that the load circuit works The controller is protected against load short circuits but cannot protect your load devices if you reverse the connection to them Now set the system voltage see pg 10 Note The controller is protected against short circuit on the solar input Dingo D4040P User Guide Using the Menu System You can move around the menu system and change settings using the button on the front of the controller There are seven top level menu items in the menu system CHRG LOAD etc see figure 5 Each menu item provides access to a sub menu and some of these sub menus lead to further sub menus A short push tells the controller to advance to the next menu item or setting value To doa short push press on the button on the front of the controller and release it immediately A long push selects moving into a sub menu or allowing you to change settings 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
3. charge and discharge from the battery or there is no battery temperature sensor fitted For example if an inverter is connected directly to the battery an external shunt and an external shunt adaptor is needed so that the controller can include the inverter current in its calculations There will also be inaccuracy due to temperature and the age of the battery Dingo D4040P User Guide What time did the battery finish charging today The FTIM screen in the DATA sub menu shows the time the controller finished charging and entered the float state see page 17 If the controller did not change from absorption to float then this will show as a dash For example if the controller started the day in float mode and stayed there all day the FTIM screen will show Are components working correctly A battery temperature sensor can be connected to your controller to improve regulation If this sensor is installed the battery temperature is shown on the TEMP screen in the DATA sub menu If it is blank no temperature sensor is attached To test your solar array the SOLV screen in the DATA menu shows the open circuit voltage of the solar array Note charging is interupted while the SOLV screen is displayed If the controller is left in this state it will automatically turn the charge back on after a period of time This is to prevent the controller being left in a non charging state How much heat can t
4. 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 during setting adjustment see page 10 and when you see the word EXIT in the HISTORY sub menu see page 16 Note external screens do not appear if there are no accessories attached If an accessory is attached the screen names will indicate the accessory type Dingo D4040P User Guide Menu System Programs 0 3 Thin arrow short push Thick arrow long push Regulator State vy CHRG CINT External Generator Control 7 7 LOAD gt LINT gt External Low Battery Disconnect Nn INT External Clear Clear OUT gt INT External Clear Clear DATA gt VMAX VMIN FTIM SOC TEMP SOLV Adjust History Data SET TIME VOLT PROG 4 4 Set Set Set Set Fig 5 Dingo D4040P User Guide Choosing your settings Failure to correctly set the system voltage VOLT and select the correct program PROG for your battery may result in damage to the battery or connected equipment Follow this procedure 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 f
5. Both are in the DATA sub menu The actual battery voltage is shown on the BATV screen What is the charge current The top level CHRG screen displays the charge current This is the total current from all charge sources The current which actually flows through the controller is called internal In larger systems there can be current which does not flow through the controller This is called external Dingo D4040P User Guide The screen displays the sum of the internal exernal currents By doing a long push on the CHRG screen you can see how much each device contributes to the total charge The first screen is called CINT and displays the internal charge The next screen s display any currents reported by external devices For details see the reference manual What is the load current The top level LOAD screen displays the load or discharge current This is the total current used by all loads A long push will display the internal load current LINT Further short pushes will display any external load currents How full is the battery The voltage level of your battery is a good 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 amp hour voltage amp temperature data to provide an estimate of the state of charge Warning SOC will be less accurate if the controller is not measuring all the
6. Dingo D4040P Positive Ground 40A Max Charge 40A Max Load Advanced Solar Charge Controller User Guide Read this before installing Ver 1 1 211012 Dingo D4040P User Guide Dingo D4040P User Guide Wiring Instructions 6 Using the Menus Choosing your Settings 10 Monitoring your System 12 Install your controller Vertically where air can circulate around it Ina dry environment out of direct sunlight Away from flammable gases or liquids Away from spiders wasps or other insects which might make nests in it Dingo D4040P User Guide Fi ig 1 UJ D Display Plasmatronics Solar Charge Regulator 12 48V 40A Alarm led Button Test terminal TEST m High current connections Control connections plug in terminal block Warning This controller is for DC current ONLY It is not an MPPT device there is no voltage conversion Suitable array max power voltages are 12 sys 16 19V 24V sys 32 38V 48V sys 64 76V Dingo D4040P User Guide Fig 2 Test terminal TEST AO soLAR OD SOLAR O BATTERY amp BATTERY O LoaD O Loap g co vor 8 E ES Soo re Do Sa Basic Connection Order Connect Battery a 2 Test Solar P
7. LDEL Min each voltage figure by 2 SET REG Setting for program number Parameter 0 l 2 3 BMAX V 15 0 14 2 15 0 14 2 EMAX V 16 0 14 0 16 0 14 0 ETIM Hr 10 0 10 0 EFRQ day 45 ABSV V 14 0 ATIM Hr 2 0 FLTV V 13 8 HYST V 0 4 40 15 0 Dingo D4040P User Guide Specifications Maximum short tern volage BAT 120 Maximum soar votage fo imum soar votaoe zAV syen oo Maximum soarvatage tora teem o _ e Maximum voltage between the G relay terminals 85 X Nesinum cierge 00 o Mesimumm conus kad 6 i ies Supply current device only battery at 12V lt Supply current device only battery at 60 46 Maximum supply current with accessories Maximum wire entry size large terminals 16mm 6 AWG Wire size Green terminal block 0 2 1 3mm 26 16 AWG 100 120 100 70 85 30 40 40 45 300 70 lt 13 lt 16 27 mA O Dingo D4040P User Guide
8. he controller take The D4040P can operate at full charge and load current up to an ambient temperature of 50 122 F Take care the temperature inside a box will be higher than outside For information on derating see apendix A4 of the D4040P Reference manual It will also work down below 20 C 4 F Dingo D4040P User Guide O The Data Menu This is a quick summary of the screens in the data submenu which are reached by a long push on the DATA screen and the values stored each day by the history function VMAX Maximum battery voltage since midnight VMIN Minimum battery voltage since midnight FTIM Time of day the controller entered the Float state if it didn t begin in float see page 17 SOC Percentage estimate of the state of charge of the battery based on amp hours in out A very rough fuel gauge Temperature being sensed by the battery temperature sensor if attached SOLV Solar panel open circuit voltage NB charging stops while displaying this screen HIST Entry point for history data display IN The amount of energy collected in Amp hours today OUT The amount of energy used Amp hours today 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 fluctuations O Dingo D4040P User Guide Retrieving historical data In addition to storing t
9. ing directly The shunt adaptor measures the current in a shunt eg SH200 converts it to digital information and sends that information back to the controller The shunt connection is isolated so the shunt can be placed in any part of the circuit Currents up to 250A can be read in 0 1 steps Dingo D4040P User Guide Gi Computer Modem Serial Interface DUSB D232 A serial interface is available which allows the controller to communicate with a computer or be remote accessed via a modem Both USB and R 232 versions are available This is a quick way to load settings or extract performance data All of the data is remotely accessible and all settings can be adjusted Windows based software is available to download the data Data can then be loaded into a spreadsheet or other applications Future accessories We will be adding new accessories Check the website for the most up to date list of accessories www plasmatronics com au Dingo D4040P User Guide Settings Used in CHRG Setting for program number Programs 0 3 Parameter o 1 GMOD 0 GOFF V GDEL Min GEXD Day GRUN Hr When programs 0 3 are selected the controller automatically uses the values in the table on the right to control its operation The voltage settings are Setting for program number shown correct for 12 Parameter 0 1 2 operation For higher voltages scale these up eg for a 24V system multiply
10. l show the regulator state BOST Boost EQUL Equalise ABSV Absorption or FLOT Float A long push on that state will manually advance the PL into the next state Or to return to the BATV screen without changing the state do a short push Low Battery Disconnect LBD To prevent battery damage due to overdischarge the controller has an optional Low Battery Disconnect LBD function which can be set to turn off the load terminal if the battery falls below a pre set voltage for a period of time Dingo D4040P User Guide 5 Short term battery voltage fluctuations caused by motors starting etc will not activate LBD Once the battery has recharged to a safe level the load will automatically switch on again This may take some time You do not have to use this feature and the controller will still operate effectively without it To use Low Battery Disconnect you need to connect your load to the regulator as described on page 7 and you should also ensure that you have chosen a program where the Low Battery Disconnect feature is activated see page 11 Note NEVER connect batteries or inverters gt 40A draw to the load terminals of the controller This can cause large currents to flow which may damage the controller Light Controller Option There is a built in light controller which can switch lights on at night When the voltage from the solar array drops the Light Controller function will switch on power to the load terminals
11. lashing 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 Short push until the time shown is correct If you pass 23 9 11 54pm it will cycle back to 0 0 midnight e When the time shown is correct long push to set it Note time setting does not affect battery charging REVERSE amp FAST FORWARD If you overshoot the setting you want and need to go back you can use reverse Do a long push The number stops flashing Do another long push The number starts flashing again but this time goes down More than 5 quick pushes will start the fast forward mode To return to normal mode stop pushing for second 2 Set the System Voltage Important a Short push to move from TIME to VOLT b Long push and the voltage will start flashing c Short push until the voltage is correct for your battery If you pass 48V it will cycle back to 12V Dingo D4040P User Guide When battery voltage is correct long push to set it 3 Set your program Important The PL comes with a number of pre set programs to make configuration easy for most installations a Short push to move from VOLT to PROG b Long push and the program number will start flashing c Short push to select the best program for your batteries d When the program shown is correct long push to set it Programs Liquid Electrolyte Battery with Low Bat
12. oday s performance data the controller can display information about the last 99 days of operation Historical performance information can be accessed from the DATA sub menu see figure 6 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 In the history display DAY is yesterday and DAY 99 is 99 days ago Note the controller actually stores 512 days data but this is only accessible via the computer interface History Mode BATV Thin arrow short push cHRG Thick arrow long push LOAD VMAX gt VMIN gt FTIM gt SOC gt TEMP gt SOLV HIST IN 4 obr Long push to adjust 0 100 DATA SET DAY 1 gt IN gt OUT gt VMAX gt VMIN gt FTIM gt SOC gt NEXT gt BACK gt EXIT RA DAY 2 gt IN OUT gt VMAX gt VMIN gt gt SOC gt NEXT gt BACK gt EXIT 5 ana A DAY 3 IN OUT VMAX VMIN gt FTIM SOC gt NEXT BACK gt EXIT 4 4 ora DATA Fig 6 DAY 99 gt IN gt OUT gt VMAX gt VMIN gt FTIM gt SOC gt NEXT gt BACK gt EXIT Dingo D4040P User Guide The Battery Charging Process When charging your battery the controller moves automatically through the following charging sequence Boost phase In this phase all available charge is used to charge the battery as quickl
13. olarity 3 Connect Solar 4 Connect Load After connection you must set the system voltage p10 tightly in the order listed on page 6 Dingo D4040P User Guide Wiring instructions For safety and to avoid damage connection of wires must be done in the following order All connections must be tight a Connect the battery first Positive to Battery Negative to Battery If the display comes on then connection is correct see figure 3 b Connect the positive wire from the solar panel s to the solar panel positive terminal WARNING ae on The controller can be 21 Sate damaged quickly by RHA reverse connection of the solar array in 32V 36V and 48V systems Battery Test first to avoid damage For safety most installa pese tion standards require fuses or circuit breakers on both sides of the battery For other connections see Fig 3 the reference manual Dingo D4040P User Guide Sate o flashes if ec Test Solar test here J sad E a Estr Fig 4 21 8 IH Tar Connect O Load c Test the solar panel connection by touching the negative wire from the solar panel onto the Test terminal TEST elf the alarm led does not flash
14. tery Disconnect option p 18 Sealed or Gel battery with Low Battery Disconnect option Liquid Electrolyte Battery with Light Controller option see 19 Sealed or Gel Battery with Light Controller option Customised setup Choosing this program will require you to set a number of additional parameters see Reference Manual 4 Set the Battery Capacity Note BCAP setting does not affect battery charging a Short push to move from PROG to BCAP b Long push and the battery capacity will start flashing c Short push to choose the correct battery capacity for your system in Ampere hours Ah Settings over 1000Ah display in thousands e g 1600 Ah shows as 1 6 Note Look for the decimal point eg 20 20Ah 20 0 20 000Ah If unsure check your battery manual or consult your battery supplier d Long push to keep the chosen value Dingo D4040P User Guide Monitoring your system This controllers s advanced monitoring functions provide you with unparalleled information about your system Here are some questions that your controller can answer 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 load has used today What voltage did the battery reach VMAX shows today s maximum voltage since midnight VMIN shows today s minimum voltage
15. y as possible When the battery is charging in the Boost phase the Boost indicator appears on the controller s screen Absorption phase The battery is nearly full To avoid excess gassing the charge current is now adjusted to keep the battery at a lower constant voltage Float phase The battery is fully charged so the controller now maintains the battery at a lower voltage If the battery voltage drops below a pre set point the controller will move back to the Boost phase automatically For flooded batteries the controller will occasionaly do a deliberate overcharge of the battery This is called Equalisation This phase helps level the charge between the different cells inside the battery by overcharging the battery for a short period It will do this several times each year Figure 7 shows how the voltage of the battery varies during the charging process The regulation settings shown in the diagram BMAX ETIM etc can all be set individually in Program 4 This caters for the requirements of customised installations Dingo D4040P User Guide For more information see the Reference Manual The pre set values provided by choosing Programs 0 2 or 3 will usually ensure good charge control without a complex setup process 4 EMAX Fig 7 a 5 5 BMAX_ gt 1 ABSV S 3 a ETIM ATIM FLTV E BRIN BOOST EQUALISATION ABSORPTION FLOAT BOOST Time A long push on wil
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