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Rev 1.39 03.10.17

Firmware Version 143 ff.

Dingo 4040P Reference Manual

D4040P

Dingo 4040P Reference Manual

Advanced Solar Charge Controller

Summary of Contents for 4040P

Page 1: ...Rev 1 39 03 10 17 Firmware Version 143 ff Dingo 4040P Reference Manual 1 D4040P Dingo 4040P Reference Manual Advanced Solar Charge Controller ...

Page 2: ...st state 6 1 2 Equalise optional 7 1 3 ABSB Absorption 7 1 4 FLOT Float 7 2 0 CHRG Menu 8 CHRG 8 CINT 8 CEXT 8 Generator Control 8 GSET 9 GMOD 9 GEXD Generator Exercise 9 GDEL Generator changeover delay 10 Generator Example 10 3 0 LOAD Menu 12 LOAD 12 LINT 12 LEXT 12 Low Battery Disconnect LSET LOFF LON LDEL 12 4 0 IN Menu 13 IN 13 IN INT 13 IN EXT 13 5 0 OUT Menu 13 OUT 13 OUT INT 13 OUT EXT 13 6...

Page 3: ...ation 20 Connecting a Temperature Sensor 21 7 5 MODE Menu Adjusting Configuration Settings 22 7 5 1 LSET GSET Controlling the load and G outputs 22 7 5 2 ESET Controlling external switches 24 7 5 3 BSET Configuring B Sense Input 24 7 5 4 BAT2 Second battery control 26 7 5 5 PWM and Slow Switching 27 7 5 6 BCAP Setting battery capacity 28 7 5 7 ALRM Setting an alarm point 28 7 5 8 RSET DFLT Resetin...

Page 4: ...ation Notes Ensure that you have followed the installation instructions on pages 3 7 of the User Guide The Dingo can be used for system voltages up to 48V It is safe to connect the power before setting the system voltage even with a 48 volt battery The Dingo is not an MPPT or voltage converter It needs a solar array with a maximum power point voltage Vmpp of approximately 17V per 12V or nominal sy...

Page 5: ...omputer modem Using an external current shunt attached to a remote current sensor DSA allows the controller to see other current flows in the system The Dingo can control larger systems by adding external switch blocks attached to the serial bus The DUSB D232 or DNET interfaces allows remote monitoring and adjustment Custom settings can be stored on a computer and uploaded into the controller Data...

Page 6: ... To get this charge cycle to repeat the Dingo must return to the boost state There are three ways that it can do this a Low Battery Voltage If the battery voltage falls below the boost return voltage BRTN for more than 10 minutes then the Dingo will switch back into the boost state The delay is necessary to prevent large short term loads causing unnecessary returns to Boost b Programmed boost cycl...

Page 7: ...ere is insufficient charge current to keep the voltage up to ABSV then the absorption timer will stop and resume when the voltage comes back up to ABSV To allow some margin the timer actually runs if the voltage is above ABSV HYST HYST is the hysteresis setting used for slow speed switching usually about 0 4V 1 4 FLOT Float In this state the battery has been fully charged The charge current is now...

Page 8: ... are given letters So 10 is A 11 is b and 12 is C This list also allows the user to check that the Dingo has found or discovered all the external devices attached to the bus This discovery process is automatic If a device is not on the list and should be then refer to section 8 4 for troubleshooting advice Generator Control The Dingo has a comprehensive generator controller built in It works in a ...

Page 9: ...2 5V GON Set SOC to start generator 0 99 GOFF Set V to stop generator 11 0 16 5V GOFF Set SOC to stop generator 1 100 GDEL Set delay before on off change 1 15 min SOC Current SOC Long push to adjust 0 100 GEXD Set days between generator exercise 2 60 days GRUN Set length of generator exercise 0 4 0 hrs GDAY View change of days since last exercise 2 60 days Active Parameter for relevant generator m...

Page 10: ... user adjustment GMOD 5 SOC ON Voltage OFF no quiet time CHRG menu Set GON GOFF GDEL GEXD GRUN as required SET REG Check these settings are correct for your battery type Mode menu GSET 2 or LSET 2 GSET if using G terminal for generator control LSET if using LOAD terminal for generator control Note when changing from prog 0 3 to program 4 the user can load the default settings for program 1 into th...

Page 11: ...en it is energised Be careful with automotive relays because they can often be poor relays requiring large coil currents Use relays from the electronics industry which generally have lower drive power The G relay terminals do not need a catch diode across the relay coil to protect from the flyback voltage This protection is built into the G terminal It can be difficult to determine what current is...

Page 12: ...g push when in LSET menu see Figure 3A Name Description Range LOFF Set voltage at which load disconnects 10 0 12 5 V LON Set voltage at which load reconnects 11 0 16 0 V LDEL Set delay before switching on off 0 15 min BATV CHRG LOAD IN OUT DATA SET LINT External LSET Toggle low battery LOFF Set voltage at which L ON Set voltage at which LDEL Set delay before load disconnects load reconnects discon...

Page 13: ...switchblock attached to the bus The sense of its operation can also be reversed i e it can turn on the terminal when the function decides the load should be disconnected This can then be used as a low battery alarm or to drive a relay to turn off other loads The connection to real switches is set up in the MODE menu See section 7 5 for details DO NOT CONNECT AN INVERTER OR ANOTHER BATTERY TO THE L...

Page 14: ...ows this balance as a percentage of the battery size Note that all system currents must be monitored by the regulator and the battery capacity must be entered by the installer at the BCAP setting before SOC will be accurate Over time a pure amp hour balance counter will drift out of line with the real battery state of charge To keep the counter better aligned with reality the Dingo automatically m...

Page 15: ...ith battery age 6 5 TEMP Display External Battery Temperature and Setting Lockout This screen displays the external battery temperature sensor reading if attached or if it s not It is also used to adjust Setting Lockout see figure 6 A 6 Setting Lockout In some cases it is desirable to restrict the ability to adjust settings so as to prevent unwanted tampering To disable settings long push on the T...

Page 16: ... down to the next day or the next day s value Short pushes move between figures for the same day NEXT goes to the next day BACK goes to the previous day The day numbers wrap around when they reach the end A short push on the EXIT screen will take you back to the beginning of that day s record A long push will exit back to the DATA screen 6 Thin arrow short push Thick arrow long push BATV CHRG LOAD...

Page 17: ...ry disconnect PROG 4 Enables customised adjustment of all settings Installation instructions for programs 0 3 are on pages 8 9 of the User Guide Set time Set battery voltage TIME VOLT PROG REG MODE EVNT Set program BATV CHRG LOAD IN OUT DATA SET Fig 7A The SET Menu NOTE Removing power to the regulator i e turning it off will reset the system time to 10 0hrs 10 00 AM The time must be set whenever t...

Page 18: ...s see below for details MODE Allows the user to adjust other configuration options EVNT Settings for the event controller CHRG Setting for program number Parameter 0 1 2 3 GMOD 0 G ON V 11 5 GOFF V 13 8 GDEL Min 10 GEXD Day 30 GRUN Hr 1 0 LOAD Setting for program number Parameter 0 1 2 3 LOFF V 11 3 L ON V 12 8 LDEL Min 10 SET REG Setting for program number Parameter 0 1 2 3 BMAX V 15 0 14 2 15 0 ...

Page 19: ... CHRG LOAD IN OUT DATA SET TIME VOLT PROG REG MODE EVNT BMAX EMAX ETIM EFRQ ABSV ATIM FLTV HYST BRTN CLIM BFRQ TCMP Set max boost voltage Set max equalisation voltage Set equalisation time Set days between eq cycles Set absorbtion voltage Set absorbtion time Set float voltage Set hysteresis Set boost return voltage Set charge current limit Set max days to between boost cycles Set temp compensation...

Page 20: ... built in charge current limit If the charge current exceeds the CLIM setting the charge duty cycle will be reduced to limit the average charge current This allows the Dingo to protect itself from overheating due to excessive charge current The maximum charge current can also be limited for small batteries where the full array current might be too much for the battery This is useful for systems wh...

Page 21: ...ire without the stripe goes to T terminal The wires may be extended if necessary without affecting the accuracy Note The DTB bolt on metal lug has no electrical connection to metal lug housing so it can be connected to either the negative or positive battery terminal 7 Temperature C V Cell TEMPERATURE COMPENSATION CURVES Normalisedto2 25V cell 20 00 10 00 0 00 10 00 20 00 30 00 40 00 50 00 60 00 2...

Page 22: ...ribed below are different from the LSET and GSET screens described in Section 2 and 3 The six internal control functions are a Low battery disconnect This also controls the LOAD indicator at the bottom of the screen b Run the backup generator This also controls the GEN indicator at the bottom of the screen c Charge a second battery Indicates when the solar input can be diverted to a 2nd battery d ...

Page 23: ...ants to disconnect the shunt load ON for regulation 11 Shunt control PWM must not be set to 2 or 3 on when function wants to disconnect shunt load OFF for regulation Don t use LSET 11 with PWM as design does not allow inversion of PWM signal SET MODE GSET Function Terminal is 0 Low battery disconnect on when function wants to disconnect battery 1 Low battery disconnect off when function wants to d...

Page 24: ...a relay These functions are configured in the LSET and GSET screens see above Regulating Wind Hydro Shunt control is appropriate for wind generators or microhydro systems which require a constant load on the charging source so the generator doesn t overspeed and destroy itself In this case the charging source must remain connected to the battery at all times Shunt control also referred to as diver...

Page 25: ...ST V Battery Push Button Light Fig 7 5 3B Push button connection 7 If the B input is not being used for this then it can be used for sensing the voltage on a second battery being charged or for providing a voltage input for the event controller VEXT Some inverter chargers such as the SP PRO can communicate to the charge controller when they want to export power to the grid Selecting BSET 3 enables...

Page 26: ...m the B sense input An external switching device such as a changeover relay will be required to switch the negative of the solar panel s from the SOL terminal of the Dingo to the negative terminal on the second battery see fig 7 5 4A Use either the Load terminal or G relay for switching the changeover relay the G relay max current is only 300mA but this should be enough to drive most relays The fo...

Page 27: ... PWM PROG 4 Only Selection Function 0 No PWM used 1 PWM on SOL terminal only 2 PWM on LOAD terminal only 3 PWM on both cause some ringing on turn off Keep wiring as short as possible and panel cable pairs together cable tie On long wiring runs at higher voltages some damping may be necessary and possibly some external clamping of transients With highly inductive wiring the transients may be large ...

Page 28: ...ther type of alarm connected to the LOAD or G terminal There is no audible alarm built into the Dingo It can send a signal or power to an external alarm of some kind The reverse function could be used to turn off a low priority load when the battery voltage is getting low System R1 Value 12V 1K 1 4W 5 24V 2K2 1 2W 5 48V 4K7 1W 5 Higher wattage resistors may be used R1 values are calculated to give...

Page 29: ... clears the block This prevents an event being immediately retriggered when it finishes STRT Setting STOP Setting EMOD TMOD Setting EOFF EON BATV CHRG LOAD IN OUT DATA SET TIME VOLT PROG REG MODE EVNT Set what determines start of Event Set value which goes with STRT Set what stops Event Set value which goes with STOP Set second condition for Event Set third condition for Event Set value which goes...

Page 30: ...is option you can wire a switch or other contact closure device between the B sense terminal green terminal block and the BAT terminal and select BSET 2 Step 4 Select a STOP setting in this table to tell the Dingo what signifies the end of the event After setting the STOP value a short push will move you to the associated setting For example if you set STOP to 1 you will see TIME Once started the ...

Page 31: ...4 Float and it s day N 15 Float external D active N Note External D will come from a bus accessory For settings 0 to 7 the low battery disconnect LBD function will override the EMOD condition and make EMOD inactive if the load should be disconnected This makes it possible to disable an event if the battery voltage is too low Settings 8 15 are the same as 0 7 but without the LBD overide SET EVNT TM...

Page 32: ...n all night STRT STOP EMOD TMOD 0 0 2 0 The first two conditions have the effect of making STRT and STOP irrelevant The STRT Whether EMOD is on 1 or off 0 if EOFF Whether STRT is on 1 or off 0 if E ON Whether STOP is on 1 or off 0 Whether TMOD is on 1 or off 0 Whether event is on E ON or off EOFF EOFF 001 Fig 7 7A Event State condition will always be on and the STOP condition will never happen In ...

Page 33: ...y direction the external devices appear in both the charge and load displays In the case of an external generator the charge display would show the generator current and the load display would always be zero In the case of an inverter charger the current could either be in either direction and either the load or charge will be non zero depending on direction 8 2 Controlling external switches An ex...

Page 34: ...4C plugs sometimes called RJ12 These loop through each device either using the two sockets on the device or using a double adaptor for single socket devices 8 4 Troubleshooting If a current measuring device does not appear in the external list of devices then check the following things a If the device address selection is set to manual check that two devices are not assigned to the same address nu...

Page 35: ...to communicate with a computer It connects to the computer s USB port The computer side is DC isolated from the Dingo side This is a quick way to load settings into the Dingo or extract performance data All of the data is remotely accessible and all settings can be adjusted Software is available for IBM compatibles to make this easy Data can then be loaded into a spreadsheet or other applications ...

Page 36: ...e the load current the time that it has been hot the battery voltage and the number of external devices attached to the serial bus For example it takes about 1 hour for the Dingo internal temperature to reach equilibrium under fully loaded conditions It is difficult to construct a simple derating table because of these factors The following information is a guide to what sort of performance can be...

Page 37: ...T T SERIAL PORT SOL BAT LOAD PUSH BUTTON POWER SUPPLY MICRO CONTROLLER G RELAY BATTERY SENSE B SENSE SHUNT SHUNT REVERSE BLOCKING FET SWITCH FET SWITCH A TEST BATTERY SOLAR BATTERY LOAD G Terminals Sensor T Temperature T B Sense LOAD SOLAR G Terminals Serial Port Test terminal Block diagram and terminal layout ALARM LED ...

Page 38: ...0 155 0 57 0 188 0 A 5 Mechanical Information Material Case Polycarbonate Heatsink Anodised Aluminium Weight in box 1 01kg 2 2lb Dimensions Width 175mm 6 9 Height 188mm 7 4 Depth 57mm 2 2 Mounting hole spacing horz 155mm 6 1 Mounting hole spacing vert 130mm 5 1 Mounting hole size 5mm 3 16 Dimensions in mm ...

Page 39: ...M FTIM FTIM SOC SOC SOC NEXT NEXT NEXT BACK BACK BACK EXIT DAY2 DAY2 DAY99 DATA DATA DATA EXIT EXIT IN IN OUT OUT VMAX VMAX DAY 3 DAY 3 DAY99 DAY 4 DAY 1 SOC BATV Set program CHRG LOAD IN OUT DATA SET Toggle function status on off GRUN GDAY CINT External GSET Set length of generator exercise View change of days since last exercise or run time if generator running LINT External LSET Toggle low batt...

Page 40: ...et length of generator exercise View change of days since last exercise or run time GTIM if generator exercising LINT External LSET LOFF L ON LDEL Toggle low battery disconnect status on off Set voltage at which load disconnects Set voltage at which load reconnects Set delay before switching INT External Clear Clear INT External Clear Clear Toggle setting lockout A showing means settings adjustabl...

Page 41: ...ge of panels ____________________________ Total solar input watts ________________________ STRT Setting STOP Setting EMOD TMOD Setting EOFF EON Other Comments ___________________________________________________________________________ ___________________________________________________________________________________________ _________________________________________________________________________...

Page 42: ...matronics com au DAY No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Date 30 days ago Comments yesterday IN Ah OUT Ah VMAX V VMIN V FTIM h SOC Customer A 6 History Data record sheet The following is the first 30 days of data stored each day in the history section of the DATA menu ...

Page 43: ...oltage for a 24 volt 80 V Maximum solar voltage for a 48 volt system 100 V Maximum continuous charge current SOL 40 A Maximum continuous load current LOAD 40 A Maximum short term load current 5 minutes 45 A Maximum G relay contact current 300 mA Battery temperature sensor range 20 to 70 C Maximum ambient temperature without derating 50 C Maximum storage temperature 70 C Supply Current device only ...

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