Magnum Energy PT-100 Owner'S Manual Download | Manualshive

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2017 Sensata Technologies

Installation

2.0 Installation

WARNING:

All installations must be performed in compliance with any applicable local

codes, and with the National Electrical Code (NEC), ANSI/NFPA 70 - for US installations,
or with the Canadian Electrical Code (CEC), CSA C22.1 - for Canadian installations.

WARNING:

Installations should only be performed by authorized personnel. These are

quali

fi

ed electricians and technicians who are familiar with solar system design and wiring

practices. It is the installer’s responsibility to determine which safety codes apply and to

ensure that all applicable installation requirements are followed. Applicable installation

codes vary depending on the speci

fi

c location and application of the installation.

WARNING:

Whenever exposed to sunlight at any intensity, PV modules can generate

current and voltage on its output wires/terminals. Working with PV circuits while the

PV system is exposed to light can result in lethal electric shock. Before making any

connections, de-energize the PV modules, either by removing them entirely from light

or completely covering their front surface with an opaque (dark) material.

CAUTION:

Review the “Important Safety Instructions” on pages ii-v before installing

the PT-100.

2.1 Pre-Installation

Before proceeding with the physical installation, read this entire Installation section to determine

how best to install your PT-100 charge controller. Also, review the installation instructions for each
component in the PV installation. The more you thoroughly plan in the beginning and become
familiar with all the components in the installation, the better the chances are that the actual

installation process will occur without incident.

2.1.1

Unpacking and Inspection

Carefully remove the PT-100 charge controller from its shipping container and inspect all contents.

Verify the following items are included:

• PT-100 Charge Controller

• 6’ Network Communication Cable (300V)

• Battery Temperature Sensor (15’)

• 6’ Extension Cable (300V)

• PT-100 Owner’s Manual

• 6’ Stacking Cable (300V)

• Ground Fault Warning Label

• Back-mount Bracket (2 pieces) with 4 screws

If items appear to be missing or damaged, contact your authorized dealer or Sensata. If at all

possible, keep your shipping box to help protect your charge controller from damage if it ever

needs to be returned for service.

Important: Save your proof-of-purchase as a record of your ownership; it will be required

if the PT-100 should require in-warranty repair.

Record the unit’s serial number in the front of this manual in case you need to provide this

information in the future. It will probably be easier to record this information now, instead of trying

to gather it after the unit has been installed.

2.1.2

Required Tools and Materials

Hardware/Materials

• Conduit, strain-reliefs and appropriate

fi

ttings

• 1/4” mounting bolts and lock washers

• Electrical

tape

• Wire

ties

Tools

• #2

Phillips

screwdriver

• Pliers

• Wire

strippers

• Drill and drill bits

• Pencil or marker

• Multimeter

• #2 -3 Slotted screwdriver

• Torque wrench

• Hammer

• Level

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Summary of Contents for PT-100

Page 1: ...PT 100 MPPT Charge Controller Owner s Manual ...

Page 2: ...connected with such installation operation use or maintenance Due to continuous improvements and product updates the images shown in this manual may not exactly match the unit purchased Restrictions on Use The PT 100 may only be used in life support devices and systems with the express written approval of Sensata Technologies Failure of this charge controller can reasonably be expected to cause fa...

Page 3: ... do not disassemble or attempt to repair Refer servicing to qualified service personnel Since a charge controller utilizes PV power and batteries power may be present at more than one point To reduce risk of electric shock ensure both battery and PV power are disconnected prior to performing maintenance Turning off the charge controller will not reduce this risk the charge controller must be total...

Page 4: ...grounded If inadvertently grounded remove source from ground Contact with any part of a grounded battery can result in electrical shock The likelihood of such shock can be reduced if such grounds are removed during installation and maintenance Read and follow the battery manufacturer s safety precautions before installing the charge controller and batteries Always verify proper polarity and voltag...

Page 5: ...ides de tout type Il n y a pas de pièces réparables par l utilisateur contenues dans ce contrôleur ne pas démonter ou tenter de réparer Confiez l entretien à du personnel qualifié Depuis un contrôleur de charge utilise des batteries et la puissance PV l énergie peut être présente à plus d un point Pour réduire les risques de choc électrique assurent à la fois la batterie et la puissance PV sont dé...

Page 6: ... source à partir du sol Pour entrer en contact avec une partie quelconque d une batterie mise à la terre peut provoquer un choc électrique La probabilité d un tel choc peut être réduite si ces motifs sont supprimés lors de l installation et la maintenance Lisez et suivez les consignes de sécurité du fabricant de la batterie avant d installer le contrôleur de charge et des batteries Toujours vérifi...

Page 7: ...Controllers Together 45 2 12 Final Inspection Tests 50 3 0 Setup 52 3 1 Adjust DIP Switch Settings 52 4 0 Operation 56 4 1 PT Front Panel Features 56 4 2 Front Panel Operation 57 4 3 MPPT Operation 62 4 4 Charger Control Operation 63 4 5 Ground Fault Detection and Interruption GFDI Operation 65 4 6 Arc Fault Protection Operation 66 4 7 Battery Temperature Sensor Operation 67 4 8 Charge Controller ...

Page 8: ...nce Adjustments 31 Table 2 5 Multiple Conductors in Raceway Cable Adjustments 31 Table 2 6 Torque Values for the DC Terminal Block 33 Table 2 7 Torque Values for the Ground Busbar 33 Table 2 8 Recommended DC Wire Overcurrent Device for PT 100 34 Table 2 9 Equipment Grounding Conductor Sizing 35 Table 2 10 Remote Compatibility Version 42 Table 3 1 Battery Type to Charge Voltages 53 Table 3 2 Summar...

Page 9: ...cking Cable 300V Rated 41 Figure 2 24 Connecting the PT 100 to the Magnum Inverter 42 Figure 2 25 Networking to Accessories Daisy Chain Configurations 43 Figure 2 26 Networking to Accessories Star Configurations 44 Figure 2 27 Wiring Multiple Controllers 47 Figure 2 28 Networking Multiple PT Controller s 48 Figure 2 29 Networking Multiple PT Controller s with Multiple Inverter s 49 Figure 2 30 Pow...

Page 10: ...on power derating when temperature is high PV short circuit and high PV input shutdown output overcurrent protection and night time backfeed reverse current protection Peak conversion efficiency is higher than 99 PV In to DC Out Low self consumption 4W in night time mode Built in programmable auxiliary relay for device control requires remote Internal data logging functionality keeps energy harves...

Page 11: ...the DC wiring terminal the switches used for configuring the PT 100 and the cable connection ports to connect accessories See Section 2 3 1 for information on how to remove this cover to access the compartment Figure 1 1 Front Features 1 3 Physical Features The PT 100 charge controller is designed to allow easy access to wiring circuit breakers and controls Its die cast baseplate with two piece co...

Page 12: ... 4 port terminal block to connect the PV and battery wires See Section 2 7 8 and 2 7 9 for information on wiring to this terminal block 10 Ground Fault Fuse this is the fuse for the Ground Fault Detection Interrupter GFDI circuitry See Section 5 5 for information on replacing this fuse 11 Ground Busbar this ground busbar is connected to the PT controller chassis and is used to tie the DC equipment...

Page 13: ...to the user to help prevent risk of electric shock fire or other safety hazard 18 Model Serial Number Label This label provides model UL CSA listings serial number information date of manufacture and charge controller specifications See the PT 100 specifications in Appendix A for more information 19 Side Knockouts dual 1 and 1 knockouts provided on each side of the DC wiring box for field wiring S...

Page 14: ...troller Also review the installation instructions for each component in the PV installation The more you thoroughly plan in the beginning and become familiar with all the components in the installation the better the chances are that the actual installation process will occur without incident 2 1 1 Unpacking and Inspection Carefully remove the PT 100 charge controller from its shipping container a...

Page 15: ...uit breaker which also provides the required overcurrent protection MPPT Charge Controller PT 100 utilizes the available maximum power output from the array to charge and maintain the battery bank Battery Bank energy storage to provide power at night or on overcast days when the PV array cannot generate the power needed Standalone inverter with an internal battery charger converts DC power from th...

Page 16: ...TS and network cables into the PT charge controller Figure 2 4 shows the location of these conduit knockouts Before removing the knockouts and mounting the PT controller think about all the different wiring requirements and select the knockout closest to the terminal to which the wire connects or whichever one works for the way your conduit or field wiring comes in Refer to Section 2 7 2 As shown ...

Page 17: ...holes total 16 7 3 18 3 cm 8 8 3 21 2 cm 1 2 8 21 6 cm 12 7 cm 5 26 4 cm RIGHT SIDE VIEW B 16 2 9 8 4 1 8 15 5 39 7 cm K NOCKOUT T RADE S IZES T OTAL A or M20 x3 B 1 and 1 x4 H OLE D IMENSIONS A 22 2 mm B 1 34 5 mm and 1 43 7 mm 8 7 64 23 32 23 8 10 3 TOP VIEW 16 1 3 6 7 cm BOTTOM VIEW 8 1 cm 3 8 2 cm 8 2 cm 4 3 cm 16 3 3 A B A A 1 2 5 cm 1 1 4 3 B 8 2 5 Overall dimensions W x H x D 8 x 15 x 4 21 ...

Page 18: ...nd 15 as shown in Figure 1 2 Before installing the cables or if leaving any ports open squirt a liberal amount of silicone dielectric compound into each port to make an effective moisture and corrosive barrier Safe Keep any flammable combustible material e g paper cloth plastic etc that may be ignited by heat sparks or flames at a minimum distance of 2 feet 61 cm from the controller Close to the b...

Page 19: ...dequate clearance around the rear heatsink fins To provide adequate ventilation allow at the minimum a clearance of 6 15 cm from the bottom surface and 1 2 5 cm from the rear and at least 1 2 5 cm from one of the side surfaces see Figure 2 7 CAUTION Do not mount this charge controller flush against any surface without using the wall mounting bracket that is provided Damage to the surface and over ...

Page 20: ...nel The keyhole slots on the back of the controller will be used to attach to the charge control bracket see the Section 2 3 6 1 1 to install the bracket on a Magnum panel Note The MP CCB is included when you purchase a Magnum Panel MMP or MP 2 Remove the 1 conduit knockout in the Magnum panel that corresponds with the conduit knockout in the PT controller 3 Use a 2 close nipple with 1 openings fo...

Page 21: ...e side of the controller and an adjacent knockout on the side of the enclosure This allows you to use a close nipple with three locknuts to secure the charge controller to the enclosure in addition to the bracket and provides a path to run the necessary wiring between the two units Mount the controller to the attached bracket using the two T15 Torx drive flat head screws Insert the close nipple th...

Page 22: ...s x 4 P1 Wall Surface Mounting Holes Ø 180 Thru Holes x 12 W P1 P1 P2 P2 P2 and Installing the Wall mounting Bracket After determining the proper mounting location use the following steps to mount the PT controller on a wall or a similar flat upright surface with the two piece mounting bracket refer to Figure 2 12 to ensure a secure mounting To secure the wall mounting bracket to a vertical surfac...

Page 23: ...the PT controller designated as P1 in Figure 2 11 onto the two 8 screws ensuring the controller is securely held in place before releasing 3 Align the two mounting holes in the bottom of the PT controller designated as P2 in Figure 2 11 over the two bottom mounting holes on the bracket designated as P2 in Figure 2 10 4 While holding the controller over these bottom mounting holes insert the other ...

Page 24: ... Wall surface mounting holes x6 Ø 180 43 6mm thru hole W PT Controller mounting holes x2 Ø 120 3mm thru hole P 2 9 cm 19 3 cm 17 7 cm 17 1 cm 6 46 16 4 cm 12 1 cm 4 4 cm 3 8 cm 9 0 cm x2 Figure 2 13 Mounting Bracket Dimensions Each Two piece wall mounting bracket PT 100 Controller 2x4 stud inside wall Figure 2 12 Surface mounting the PT 100 Controller ...

Page 25: ...disconnects and all common wire connection points to be connected together accessible from the front and marked in an easy to install pre wired enclosure Figure 2 14 PT 100 Controller System Wiring Note 1 When PV system is not solidly grounded disconnecting means are required in both legs of PV circuit Note 2 The battery negative to ground connection is only made inside the PT 100 controller If an...

Page 26: ...egative correlation coefficient meaning the two variables are in an inverse relationship For PV modules as the temperature goes down the module voltage increases 2 5 1 PV Input Voltage Limits for the PT 100 The following PV voltage levels are required for the PT 100 controller to operate refer to Table 2 1 and also see Figure 4 8 PV Array s Lower Maximum Power Voltage VMP LOW Level The PV array sh...

Page 27: ...able gives a correction factor that can be applied to determine the temperature compensated voltage 1A Calculating Module s Maximum Output Voltage VOC MAX To calculate the module s maximum output voltage based on the module manufacturer s temperature coefficient method at the lowest recorded local temperature use one of the formulas below a If coefficient in percentage use VOC MAX VOC 1 TLOW TSTC ...

Page 28: ... see Table 2 1 240V 48 volt system 3 What is the maximum number of modules that may be installed in series 240V 43V 5 58 5 modules rounded down to the next whole number Answer You should connect no more than 5 of these modules in series to ensure the array s voltage stays below the PT 100 s maximum PV input voltage level Find the maximum number of PV modules in series to use with the PT 100 with α...

Page 29: ... L TSTC αVOC V VOC UPP module s upper output voltage VOC module s rated open circuit voltage at STC 25 C TAVG L module s temperature at the lowest average temperature TSTC module s temperature at STC 25 C αVOC V temperature coefficient of VOC provided as V Info When lower than average temperatures occur the module s VOC may rise above the PT 100 s upper MPPT voltage limit This is not of great conc...

Page 30: ... free standing plenty of air circulation around them 25 C TSTC module s temperature at STC 25 C αVMP V temperature coefficient of VMP provided as voltage Info Different PV mounting methods cause the module temperature to rise and the modules to operate at lower maximum power point voltage levels There are three typical PV array mounting methods 1 Parallel to Roof the modules are flat against the r...

Page 31: ... roof with minimum clearance 35 C The controller is connected to a 48 volt nominal battery bank where the highest charging voltage required will be 66 volts A Find the maximum number of PV modules that can be connected in series that will stay below the upper VOC level 1 What is the module s upper VOC level VOC UPP 41 18V as calculated below VOC UPP VOC TAVG L TSTC αVOC V VOC UPP 37 8V 1 C 25 C 14...

Page 32: ...point i e String Combiner The maximum current for each series string source circuit is the module s rated short circuit current ISC x 125 IMAX ISC x 1 25 2 PV Output Circuit conductors between the photovoltaic source circuit s and the DC uti lization equipment i e Charge Controller The maximum current for this circuit is the sum of the PV source circuit maximum currents in parallel IMAX ISC x 1 25...

Page 33: ...eration can result in reduced ampacity which often results in a conductor that is larger than the conductor sized for continuous current o Conduit Fill Correction Conduit fill refers to the number of current carrying wires of a particular size and type allowed in a particular size of conduit Adjustments to the conductor ampacity is required if there are more than three current carrying conductors ...

Page 34: ...l temperature is lower they do have an advantage Their higher ampacity rating can be used when applying derating factors due to ambient conditions or when exceeding more than 3 current carrying conductors in conduit Info Remember to consider both ends of the conductor when derating For example if one end of the conductor is connected to a circuit breaker with a 75 C terminal and the other end is c...

Page 35: ...the OCPD for continuous operation is on top of the 125 multiplier to the module s rated ISC value for high irradiance conditions when sizing the PV source and PV output circuits for maximum circuit current Info If no temperature rating is marked on the terminals then a 60 C limit is used for circuits rated at 100 amps or less and for cables 14 to 1 AWG For circuits rated greater than 100 amps and ...

Page 36: ... Adder is greater than 30 C then these two temperatures become the effective ambient temperature Eff Temp value Use this effective temperature to determine the appropriate Correction Factor from Table 310 15 B 2 a Rooftop Temperature Adder Rooftop Add Conductors raceways exposed to sunlight on a roof require the ambient temperature to be increased based on the distance from the roof using a Temper...

Page 37: ...rent carrying conduc tors bundled together is 80 0 80 2 Temperature Correction Factors ambient temperature rooftop adder there is no derate based on temperature The ambient temperature is 26 C so there is no derate as it is below 30 C There is no rooftop adder because the PV source conductors are not installed close to rooftop b Find the conductor size after derating factors have been applied Lowe...

Page 38: ...r The ambient temperature is 26 C and there is a rooftop adder of 28 C per Table 310 15 B 3 c because the PV output conductors are installed 2 from the rooftop The ambient temperature 26 C rooftop adder 28 C give an effective temperature of 54 C A temperature derate is required since this is greater than 30 C Using Table 310 15 B 2 a a USE 2 90 C cable at a temperature of 54 C uses a Temp Factor d...

Page 39: ...actors have been applied for ambient temperature or number of conductors are limited to the following ratings 14 AWG 15A 12 AWG 20A 10 AWG 30A Table 2 3 Ambient Temperature Adjustments Conductor ampacities must be derated when in ambient temperatures greater than 30 C 86 F Find the allowable ampacities specified in the ampacity tables from Table 2 2 and multiply by the appropriate correction facto...

Page 40: ...from Table 310 15 B 3 c in the National Electrical Code 2014 Edition Table 2 5 Multiple Conductors in Raceway Cable Adjustments Number of Conductors Conduit Fill Adjustment Factor 4 6 80 0 80 7 9 70 0 70 10 20 50 0 50 21 30 45 0 45 31 40 40 0 40 41 and above 35 0 35 Data taken from Table 310 15 B 3 a in the National Electrical Code 2014 Edition Three current carrying conductors in conduit or bundl...

Page 41: ...charge controller Negative should not be bonded to ground anywhere else in the system to ensure the GFDI circuit operates correctly Use only copper wires with a minimum temperature rating of 75 C The wire sizes recommended are based on the ampacities given in Table 310 16 in conduit of the NEC ANSI NFPA 70 for 75 C 167 F copper wire and based on an ambient temperature of 30 C 86 F The NEC requires...

Page 42: ... connections are correct you should use an accurate quality torque screwdriver wrench It is highly recommended to go back over all fasteners and re torque 5 days after the initial installation and every 6 months thereafter CAUTION DC power wire connections that are under torqued could become loose and result in a fire hazard On the other hand over tightening a screw bolt could cause the fastener t...

Page 43: ...sconnect is required The disconnects in the system must be able to be manually operable without exposing the operator to contact with live parts grouped together and identified be readily accessible and plainly indicate whether they are in the ON closed or OFF open position For information on correctly sizing the OCPD for the PV source and PV output conductors see Section 2 6 For the PT 100 output...

Page 44: ... allow fault currents to properly operate overcurrent devices If equipment is removed which disconnects the bonding connection between the grounding electrode conductor and exposed conducting surfaces a bonding jumper must be installed while the equipment is removed The DC equipment grounding conductor is sized per Table 2 9 and connected to the DC equipment grounding busbar on the charge controll...

Page 45: ...arge controller will be defeated Info If multiple PT controllers are connected together i e stacked see Section 2 11 for information on setting up the GFDI for a multiple controller system 2 7 7 1 GFDI Label In a photovoltaic system that has a Ground Fault Protection device the NEC requires the installer to apply a warning label near the ground fault indicator in a visible location stating the fol...

Page 46: ...ue values for these screws Note Two Torx head screws on each end of the busbar are used to hold the ground busbar in place DO NOT remove these two screws WARNING Before making any wire connections make sure the charge controller is not connected to the battery and there is no PV power cover all panels and open all PV source breakers fuses DO NOT close the PV or battery circuit breaker to connect p...

Page 47: ...ires ground positive and negative from the charge controller to the battery bank 2 Connect the ground wire green or bare copper from the charge controller to the battery ground terminal 3 Connect the positive wire red or black from the charge controller to a dedicated battery breaker ensure breaker is open then to the battery positive terminal 4 Connect the negative wire white from the charge cont...

Page 48: ...uld be connected to the negative battery post However when connecting the BTS the BTS terminal should NOT be placed directly against the battery post Instead all power cables charge controller and inverter should be placed on the battery terminal first then place the BTS terminal on the power cable terminals Refer to Figure 2 19 to stack the battery cable and BTS terminal hardware correctly Incorr...

Page 49: ...res voltage or current it must be provided externally and routed through the relay This relay is not intended to directly provide power Rather this relay can be used to send a signal to operate the coil of another higher amperage device that does the actual switching of power An in line fuse rated up to 5 amps up to 30 VDC or 0 5 amp above 30 VDC to 100 VDC must be used to protect all power circui...

Page 50: ...d of this cable is connected to the inverter and the other end is routed to the controller and connected to the NETWORK port inside the controller s wiring area See Figure 2 24 Figure 2 21 NETWORK Communication Cable 300V Rated Figure 2 22 shows the EXTENSION cable It allows the Battery Temperature Sensor BTS to be connected to the controller This is a 6 1 83 m 4 conductor telephone type cable wit...

Page 51: ...n when networked with a PT controller However the remote is required to have a minimum software version to monitor and set up the PT controller Refer to Table 2 10 to determine the minimum remote version required for viewing and configuring the PT controller If a remote is used that does not include PT menus the inverter s charger settings values i e Battery Type Absorption Time and the inverter B...

Page 52: ...er charger PT 100 CHARGE CONTROLLER ME BMK BATTERY MONITOR 2 way Phone splitter ME ARC ADVANCED REMOTE 2 way Phone splitter Note The ME AGS N or PT 100 must be the first network device connected to the inverter followed by the ME BMK and whatever device wasn t used as the first network device ME AGS N or PT 100 is connected after the ME BMK Note The ME AGS N or PT 100 must be the first network dev...

Page 53: ... 100 CHARGE CONTROLLER ME BMK BATTERY MONITOR Two 2 way Phone splitters ME ARC ADVANCED REMOTE Networking the PT 100 with Other Network Devices Star Configuration using a 3 way splitter Magnum Inverter charger ME AGS N NETWORK AGS ME BMK BATTERY MONITOR 3 way Phone splitter ME ARC ADVANCED REMOTE PT 100 CHARGE CONTROLLER Networking the PT 100 Star Configuration using 2 way splitters Networking the...

Page 54: ... any charge controller see Figure 2 27 3 Each controller must be connected to each other using a Stacking cable connected in a daisy chain style as shown in Figures 2 28 or 2 29 4 No more than seven PT controllers can be connected together in a stacked configuration 5 When multiple controllers are mounted together there must be at least 1 between each controller to allow for free air flow and to p...

Page 55: ...ring All wiring within the PT controller s wiring compartment must have insulation rated for the highest voltage within this compartment When wiring the network cable and stacking cables from one controller to another as shown in Figure 2 27 ensure the supplied yellow communication cables with 300 volt rated insulation are used see Section 2 10 for more information on these cables Networking Multi...

Page 56: ...0 Controller Master PT 100 Controller Slave 1 PT 100 Controller Slave 2 PV PV PV ARRAY PV PV PV ARRAY PV PV PV ARRAY 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 DC Shunt WIRING LEGEND NEGATIVE POSITIVE DC GROUND B B BATTERY TEMP SENSOR INVERTER DC DISCONNECT TO PRIMARY DC GROUND SYSTEM BTS Internal GFDI fuse NETWORK Cable 300V To PT 100 Master Controller ...

Page 57: ...e NE TW ORK NE TW ORK 1 2 3 4 5 6 7 8 9 Stack Address C01 Stack Mode Enabled Master PT Controller address C01 NE TW ORK 1 2 3 4 5 6 7 8 9 Stack Address C03 Stack Mode Enabled 1 2 3 4 5 6 7 8 9 STACK Cable STACK Cable Slave 1 PT Controller address C02 Slave 2 PT Controller address C03 Stack Address C02 Stack Mode Enabled 2 min 2 min Figure 2 28 Networking Multiple PT Controller s ...

Page 58: ...ck Mode Enabled 2 min Multiple Magnum MS PAE Series Inverter Charger s Master PAE Inverter to MS Port on router Slave 1 PAE Inverter to SL1 Port on router SL3 P1 MS SL1 SL2 P2 P4 P3 P5 P6 NETWORK Cable to NETWORK port on one of the inverters and to NETWORK port on Master PT 100 ME AR TR Advanced Router REMOTE Cables to REMOTE Ports on R outer ME AR TR and PAE inv erters REM O TE REM O TE STACK STA...

Page 59: ...terminal of the battery disconnect breaker that is located on the battery positive side Use the black test probe of the DC voltmeter and touch it to the battery negative terminal on the PT controller If the polarity is correct the multimeter will show a positive indication 2 If the battery voltage is within the PT 100 input requirements and polarity is correct apply battery power to the PT control...

Page 60: ...uto scrolling thru the operational screens If the power up test did not perform correctly or a fault occurs F code displays refer to Section 5 0 Maintenance and Troubleshooting for diagnostic help Note 1 The system voltage switches are set to AUTO default from the factory If the battery voltage is well below the nominal battery voltage and the voltage that was displayed i e 12 24 or 48 volts is in...

Page 61: ... inverter and remote the remote is used to set up and or control the PT controller s operation Refer to the appropriate remote owner s manual for setup information see Section 2 10 3 3 1 Adjust DIP Switch Settings The DIP Dual In line Package switch includes 10 individual slide switches that can be set to the UP on or DOWN off position As a standalone PT controller the arrangement of the 10 switch...

Page 62: ...4 1 VDC 13 6 VDC Not Allowed Not Applicable 24 VDC 28 2 VDC 27 2 VDC 48 VDC 56 4 VDC 54 4 VDC Note 1 Specifications for Concord Lifeline Series AGM batteries Note 2 Specifications for East Penn Deka Discover and Trojan AGM batteries Table 3 1 Battery Type to Charge Voltages Switches 3 4 System s Battery Voltage Four 4 settings are available for your system s nominal battery voltage as shown below ...

Page 63: ...enables Stack mode and allows the PT controller to be networked i e connected to a Magnum inverter and remote Once the PT controller is networked the absorption time is now determined by the remote and DIP switches 7 8 and 9 are now used to determine the address number of the controller If multiple controllers are stacked together a unique and valid address number C01 to C07 for each controller is...

Page 64: ... SW6 DN SW7 SW8 SW9 Absorption Time controller address number when stacked Auto Determine SW7 DN SW8 DN SW9 DN 1 Hour C01 SW7 DN SW8 DN SW9 UP 2 Hours C02 SW7 DN SW8 UP SW9 UP 3 Hours C03 SW7 DN SW8 UP SW9 DN 4 Hours C04 SW7 UP SW8 UP SW9 DN 5 Hours C05 SW7 UP SW8 UP SW9 UP 6 Hours C06 SW7 UP SW8 DN SW9 UP 7 Hours C07 SW7 UP SW8 DN SW9 DN SW10 Stack Mode Disabled SW10 DN Enabled SW10 UP Switches 7...

Page 65: ...roller is in BULK blue ABSORB yellow FLOAT green or EQUALIZE all 3 charge LEDs on Fault LED Indicator The FAULT LED red illuminates to indicate when a fault condition exists When the FAULT LED comes on the display also shows the F fault code which is used to determine the fault condition For details about the fault codes see Section 5 3 Troubleshooting Based on Fault Codes Aux Auxiliary Relay LED ...

Page 66: ...lay While manually scrolling thru the displays the Power Status code which may not have shown while auto scrolling will always show after the first four operational displays along with the fault display if active Info If the display is auto scrolling the Power Status code will only show if the controller s output power is being limited P03 P04 or P05 Otherwise only the first four operational displ...

Page 67: ...V to maintain the battery at the Absorb target voltage2 OFF OFF Blink Float charge stage power limited1 the controller is in the Float charge stage but current is being limited to the battery ON 1st 2 sec ON 2nd 2 sec ON 3rd 2 sec Equalize charge stage the controller is in the equalization charge mode regulating the current from the PV to maintain the battery at the Equalize target voltage2 Note E...

Page 68: ... rate setting in the remote if networked Power Limited Internal High Temperature the temperature inside the PT controller is high the P03 power code will show if the output current is being limited in an attempt to prevent the controller from shutting down Note The charge status LED indicator that is active will blink during this power status Power Limited Internal Frequency the controller include...

Page 69: ...ing the fault display in sequence with the other operational displays Figure 4 4 Hard Fault Conditions Fault Code Display LED Indicators OFF Fault LED Indicator is ON Hard Fault Figure 4 5 Soft Fault Conditions Fault Code Display LED Indicators OFF Fault LED Indicator is BLINKING Soft Fault Soft Faults Some fault conditions will not cause the controller to shut down With these particular faults th...

Page 70: ...s power up test all the LED indicators and each segment of the display will come on the internal alarm beeps three times and right before the power up test finishes the PT firmware version and the nominal DC detected voltage are displayed see Figure 2 27 Info You can check the pushbutton response by pressing the SELECT or RESET pushbutton and listening for a beep after an active function e g manua...

Page 71: ... it continues to operate at the correct MPP When the current the batteries can accept is lower than the PV source can provide or the batteries are close to being fully charged and are no longer able to absorb the incoming current the controller can no longer operate the panel at its maximum power point When this happens the MPPT algorithm in the PT controller moves the PV panel operating point awa...

Page 72: ...voltage has been reached Absorb charging provides the batteries with a constant voltage determined by the Battery Type setting and reduces the charging current in order to maintain the Absorb Voltage setting The controller s ABSORB yellow LED comes on to indicate it is in the Absorb charge stage for a time period determined by the Absorb Time setting then switches to float charging Info While abso...

Page 73: ...rflow Once the equalization charge cycle has finished add water as needed to ensure the plates are covered Refer to your battery manufacturer to either leave the filler caps screwed on if vented leave them on loosely or remove them and cover the opened cell tops with a folded paper towel Only equalize when you are present to monitor the batteries during the entire charging cycle How often should I...

Page 74: ...e charge push SELECT RESET for 2 seconds 4 5 Ground Fault Detection and Interruption GFDI Operation The GFDI circuit inside the PT controller has the ability to detect indicate and interrupt a ground fault in the PV array which may be required according to the National Electrical Code 690 5 If the PV array is wired in a negative grounded configuration the internal 0 5 amp GFDI fuse should provide ...

Page 75: ...nintentionally starts opening This can be caused by damaged conductors or loose corroded connections either inside a PV module or on a PV system component 4 6 1 AFP Test Switch The arc fault test switch see Figure 4 11 is provided to determine whether the arc fault detection circuit in the PT controller is functioning properly When the arc fault test button switch is pressed and released a simulat...

Page 76: ...the batteries if they are subjected to large temperature changes Info When the BTS is connected the PT controller uses a value of 5mV C Cell from 20 C to 54 C to change the charge voltage based on temperature Info If the BTS cable is damaged and the wires are shorted the display will indicate a F05 BTS Shorted Fault message If the BTS has been connected and later the cable has been cut or is disco...

Page 77: ...ether the charge controller s fans start or stop Info The PT 100 delivers full output current 100 amps in ambient temperatures up to 40 C 104 F Due to the fan cooling this level of performance can be achieved in closed rooms The PT 100 does remain operational above 40 C 104 F but the charger output level is reduced to protect the internal components from overheating see Figure A 1 4 9 PowerSave Op...

Page 78: ...he relay is no longer engaged has disengaged the LED will turn off Info For information on configuring the aux relay for operation when networked refer to the appropriate remote control manual includes the revision that provides the PT Aux Relay menu see Section 2 10 3 4 11 Internal Beeper Operation The PT controller includes an internal beeper or buzzer that sounds after one of the pushbuttons on...

Page 79: ...emote control allows you to monitor and customize the operating parameters for your PT controller such as viewing daily peak power levels viewing power harvested viewing fault history information for troubleshooting viewing control charge stages and much more Info The controller uses the remote settings when networked and continues using these settings even if the remote is disconnected1 These set...

Page 80: ...display until the C0 C01 to C07 network address display appears see Figure 4 14 Note DIP switches 7 8 and 9 are normally set from the factory will all switches in the DOWN position If DIP switch 10 is set UP to enable the controller stacking feature and DIP switches 7 8 and 9 are still in the DOWN position the controller address shows as C00 This controller address C00 is not a valid stacking addr...

Page 81: ...ntroller is at its maximum output current can show Relay Status Status of the relay of the master controller engaged or disengaged b PV Voltage Highest PV voltage to any controller c Battery Voltage Battery voltage to the master controller d Target Voltage Temperature compensated voltage of the master controller Note If a BMK is installed in the system the BMK s DC voltage will be used when determ...

Page 82: ...y occurred on only one controller most likely the controller designated as the master 4 13 4 Network Control from Remote to Stacked Controllers When multiple controllers are enabled to stack and network the PT control menus in the ME ARC remote version 4 0 or higher and the ME ARTR Advanced Router can be used to control the multi controller system On the following PT control menus any setting sele...

Page 83: ...e controller is designed to provide you with years of trouble free service The following information is provided to help you keep your PT 100 charge controller in optimum operational condition 5 1 1 Recommended Charge Controller Care Even though there are no user serviceable parts it is recommended that the following maintenance steps should be performed annually to ensure optimum performance of t...

Page 84: ...ower detected on the PV input terminals i e PV to PV for more than 24 hours This can be caused by an open breaker to the PV input a bad PV wire connection to the PV input terminals on the PT controller or a long period 24 hours of no sun or very low sun Remedy The fault will automatically clear and the controller will resume operation once the voltage to the PV input terminals is 5 volts above the...

Page 85: ...PV array to the battery terminals or the battery bank is being charged by some external means and the voltage has exceeded 68 VDC Remedy The fault will automatically clear and the controller will resume operation once the voltage to the battery input terminals is 66 4 volts DC This fault can also be cleared manually by pressing the RESET pushbutton for one second once the voltage falls below 68 VD...

Page 86: ...ay be damaged faulty components inside the controller and it will require repair FAULT LED ON Internal Phase Fault The PT controller turned off to help protect itself because one or more of the internal phases is faulty or the phase signals are not in sync with each other Remedy Press the RESET pushbutton for one second which should clear the fault and turn the controller on If fault cannot be cle...

Page 87: ...e fault has cleared verify the controller comes on If the fault cannot be cleared there may be damaged faulty components inside the controller and it will require repair FAULT LED ON Internal Hardware Fault The PT controller turned off to help protect itself because the redundant hardware protection circuit that monitors the internal temperature has exceeded a safe operating limit Remedy Press and...

Page 88: ...ommunicating on the network but now it is no longer receiving any communications from the Magnum inverter or from another controller Note The controller continues to run with this fault Remedy This fault can be caused by 1 A stack or network cable was damaged or disconnected a Examine the cables for any damage and replace if needed or try another remote and or stack cable 2 The network or stack ca...

Page 89: ...e UP position stack enabled on every controller connected together in a stacked configuration The fault will automatically clear and the controller will resume operation once the correct stack address is set FAULT LED BLINKING Battery Voltage Fault This fault indicates that there is a large battery voltage difference between the master controller and a slave controller This fault is only allowed o...

Page 90: ...re leakage occurs between a current carrying conductor in the PV system and an equipment grounding conductor or grounded surface device Before replacing the fuse it is important that the ground fault is located and corrected To remove and replace the GFDI fuse 1 Remove the access cover see Section 2 3 1 2 Locate the GFDI fuse holder see Figure 5 1 3 Use an insulated standard flat blade screwdriver...

Page 91: ...ark then remove any connection between the electronics section and the wiring conduit box Info Before removing any connection and wires mark them to correspond with their component connection and terminals to prevent incorrect wiring when reconnecting 3 Remove the two lower screws 8 32 x 3 8 Phillips that hold the electronics section to the wiring conduit box 4 While using one hand against the fro...

Page 92: ...e controller continues to show an internal fault perform a power reset using the procedure below 5 7 2 Performing a Power Reset AKA Hard Reset To perform a power reset also known as a hard reset 1 Remove all power PV and battery to the charge controller this is normally done by opening the PV input and battery input disconnects 2 Remove any cable that is plugged into any accessory port i e BTS REM...

Page 93: ...downloading and installing the update The PT 100 controller uses a USB Micro B port connector see Figure 5 4 to connect a Windows based computer to download a firmware updates Note Installing new firmware resets your PT 100 controller to its factory default settings However if used in a standalone installation i e not networked the DIP switch settings will reload If networked with a Magnum inverte...

Page 94: ... two overlapping circuits Over Temperature Protection On transformer and MOSFETS Certifications ETL listed to UL cUL 1741 Certified to CSA C22 2 No 107 1 01 for use in Canada CE for use in Europe Warranty 5 years parts and labor Environmental Specifications Operating Temperature 20 C to 60 C 4 F to 140 F Non operating Temperature 40 C to 70 C 40 F to 158 F Operating Humidity 0 to 95 RH Non condens...

Page 95: ...t Curve Figure A 2 Output Current vs Battery Voltage Curve A 2 2 Output current verses Battery Voltage The following curve shows the PT 100 s output current at different battery voltage levels The output current of the PT 100 is consistent throughout it s battery voltage range 60 65 70 75 80 85 90 95 100 105 10 20 30 40 50 60 70 Continuous Current Adc Battery Voltage Vdc PT 100 vs Competition Curr...

Page 96: ... Voltage The following curve shows the PT 100 s output power at different PV input MMP voltage levels The output power of the PT 100 is consistent throughout it s PV input MMP voltage range 4 4 5 5 5 5 6 6 5 7 60 80 100 120 140 160 180 Maximum Power Kw MPP Voltage Vdc PT 100 vs Competition Maximum Power vs MPP Voltage PT 100 Competition ...

Page 97: ...r Kit The ME BMK and ME BMK NS Battery Monitor Kit is a single battery bank amp hour meter that monitors the condition of the battery provides information to let you know how much energy is available and lets you plan your electrical usage to ensure the battery is not being over discharged Note The DC shunt is included with MMP and MP Series enclosures Order the ME BMK NS version when installed wi...

Page 98: ...t to bubble and mix This helps reduce stratification Float Stage During the third stage of three stage charging the voltage and current are reduced to a level that will trickle charge or maintenance charge the battery This assures the battery remains fully charged even while sitting Fuse or Disconnect When current exceeds a preset limit the fuse or disconnect will fail before the wiring or equipme...

Page 99: ... conductors in the PV circuits derated by the following conditions of use factors 1 Conduit Fill Factor Fill Factor When more than three current carrying conductors are in conduit or bundled together in continuous lengths 24 inches then divide by the Conduit Fill Factor from Table 310 15 B 3 a 2 Temperature Correction Factor Temp Factor If the average ambient temperature Avg Temp in addition to th...

Page 100: ...b the largest conductor size between the two is the minimum required conductor Conductor Sized to the Continuous Current AWG Temp Conductor Sized after Derating Factors AWG Temp Minimum Required Conductor Size AWG Temp PVSOURCE lCONT PVSOURCE lDERATE PV Source PVOUTPUT lCONT PVOUTPUT lDERATE PV Output Step 5 Size the Overcurrent Protection Device OCPD to protect the selected conductor Ensure the s...

Page 101: ... ASC After the completion of service under this limited warranty the product will be returned prepaid to the original purchaser via non expedited surface freight within the contiguous United States and Canada this excludes Alaska and Hawaii 6 If Sensata repairs or replaces a product its warranty continues for the remaining portion of the original warranty period or 90 days from the date of the ret...

Page 102: ...PT 100 Owner s Manual PN 64 0067 Rev B Magnum Energy Products Manufactured by Sensata Technologies www SensataPower com ...

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