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Rev 6.3.0 12.09.16

PL Reference Manual

36

SOLAR

(SOL-)

LOAD-

BATTERY

(BAT-)

REVERSE

BLOCKING

FET SWITCH

FET SWITCH

SHUNT

SHUNT

PUSH

BUTTON

POWER

SUPPLY

MICRO

CONTROLLER

DISPLAY

TEMPERATURE

SENSOR(T+,T-)
B- SENSE INPUT (B-)
SERIAL PORT

“G” Terminal

(BAT+)

SOLAR BATTERY LOAD

REVERSE
BLOCKING
FET SWITCH

FET SWITCH

SHUNT

SHUNT

POWER

SUPPLY

MICRO

CONTROLLER

DISPLAY

TEMPERATURE
SENSOR (T+,T-)

BATTERY SENSE

SERIAL PORT

"G" Terminal

NEG NEG NEG

-

-

-

(B+ SENSE,
B- SENSE)

+

+

+

SOL
POS
BAT
POS

LOAD
POS

PUSH
BUTTON

A

A.4.1 Block Diagram of PL20/40 Hardware

The PL Controller is designed for common positive installations (i.e. switches solar and load in the negative wire).
It has a reverse blocking mosfet switch between the SOL- terminal and the BAT- terminal and a mosfet
switch between the LOAD- terminal and the BAT- terminal. There is also a low current mosfet switch
between the ‘G’ terminal and the BAT- terminal used to drive a generator control or alarm relay.

A.4.2 Block Diagram of PL60/80 Hardware

Note: Common positive configuration (ie switches solar and load in the negative wire)

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Summary of Contents for PL20

Page 1: ... 0 12 09 16 PL Reference Manual 1 SOLARCONTROLLER PL20 BAT SOL BAT LOAD 12 48V 20A CHARGE PLASMATRONICS P LASMATRONIC S BOOST Ah N1271 Reference Manual Plasmatronics PL Series Advanced Solar Charge Controller ...

Page 2: ...7 2 0 CHRG Menu 8 CHRG 8 CINT 8 CEXT 8 Generator Control 8 GSET 8 GMOD 9 GEXD Generator Exercise 10 GDEL Generator changeover delay 10 Generator Example 10 Generator Start Relay Wiring 11 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 0 DATA Menu Retrieving Performance Dat...

Page 3: ... Connecting a Temperature Sensor 21 7 5 MODE Menu Adjusting Configuration Settings 22 7 5 1 7 5 2 LSET GSET 22 Diversion Control 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 28 7 5 7 ALRM 28 7 5 8 RSET 28 7 6 EVNT Menu Event Control 29 Using the Event Controller 29 Examples 33 A 0 Appendices 34 A 1 Accessories 34 A 2 Spe...

Page 4: ...the LCD display reaches 60 C it will darken and may become unreadable however it will return to normal when it cools down 0 1 Introduction Please read the User Guide before reading this manual In most cases the User Guide provides all the information needed for effective installation of the PL and there is no need for the user to read this Reference Manual However in some cases users with a good u...

Page 5: ...for measuring external voltages A communications interface is provided for accessories including remote shunt adapters PLS2 an RS232 adapter to communicate with a computer modem PLI and a PLA unit which provides additional alarm outputs and syncronisation of multiple regulators as well as an RS232 output The PLI and PLA allows remote monitoring and adjustment Custom settings can be stored on a com...

Page 6: ...is charge cycle to repeat the PL 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 PL will switch back into the boost state The delay is necessary to prevent large short term loads causing unnecessary returns to Boost state b Programmed boost cycles optiona...

Page 7: ...egin at 9am on the appropriate day If ETIM is 0 then equalisation will not occur To prevent the controller being trapped in equalise mode for a long time because there is inadequate charge current to reach the equalise voltage the PL terminates equalise after 4 days 1 3 ABSB Absorption In this state the PL tries to keep the battery voltage constant while the last part of the battery charging occur...

Page 8: ...nal shunt and PLS2 CINT From the charge screen a long push displays CINT Charge Internal This is the real time solar charging current in amps CEXT From the CINT screen a short push displays CEXT Charge External This is the real time external charging current measured using an optional shunt and PLS2 Generator Control The PL has a comprehensive generator controller built in It works in a similar wa...

Page 9: ... to G ON Turn off when SOC rises to GOFF GOFF can be set to greater than 100 to allow some overcharge Quiet time applies 3 Manual start When started in the GSET screen the generator will run for GRUN hours 4 No quiet time Turn on when battery voltage falls to G ON for GDEL minutes Turn off when the voltage rises to GOFF for GDEL minutes 5 No quiet time Turn on when the State of Charge SOC falls to...

Page 10: ...changeover delay A programmable delay in minutes is used to prevent any large transient loads from triggering a generator change of state on off Default programs are set to 10 minutes Note Do not confuse GSET CHRG menu and LSET LOAD menu with screens of the same name in the SET MODE menu They perform different functions Generator Example The generic programs PROG 0 3 use voltage driven generator c...

Page 11: ...enerator but consult generator manual The relay can be replaced with a suitable visual indicator LED resistor or a small lamp to show the user when to start the generator Max current 120mA Typically contact closure starts generator but consult generator manual Since the G Contacts are voltage free the relay can be switched in the negative or positive wire negative wire switching shown Many install...

Page 12: ...oad Control LBD and LVD If correctly configured equipment connected to the battery the load will be turned off when the LOAD or G terminal is turned off Once turned off the load will not be reconnected until the voltage rises enough to indicate some recharge has taken place This feature is optional and can be disabled either by connecting the user load directly to the battery or by setting the par...

Page 13: ...ort push displays EXT External Ah IN This is the running total of external Ah input and measured using an optional shunt and PLS2 A long push will clear the EXT running total 5 0 OUT Menu OUT The OUT screen gives a running total of Amp hours Ah or energy that has been used during the day since midnight This total is the sum of Ah used by equipment connected to the LOAD terminal and any external Ah...

Page 14: ...from the current day readings 6 1 6 2 VMAX and VMIN VMAX and VMIN respond very slowly to changes in battery voltage This allows them to ignore short term voltage fluctuations Warning at reset or initial start up they can take up to 40 minutes to reach the correct value 6 3 FTIM Float time Display FTIM indicates the time of day that the regulator changed from the ABSB Absorption state to the FLOT F...

Page 15: ...n the SOC screen will reset the unit to 100 The SOC figure should be treated with caution as there are several reasons that it may be inaccurate The PL does not automatically have knowledge of the whole system It only knows what you tell it For SOC to work at all the PL must be measuring all charge Ah in and discharge Ah out If the battery can charge or discharge without the PL knowing SOC will no...

Page 16: ... unable to change your settings after following the above procedure you may need to obtain the settings lockout link Contact your dealer If you wish to obtain the link yourself the Part is Farnell 510 920 2mm pitch You will need to temporarily disconnect the cable of any accessory installed in the system The link is installed on the 8 way pin header under the lid of the PL controller under lower l...

Page 17: ... adjust each setting individually If you find you are unable to change your settings it may be because the lockout setting is activated This setting is designed to prevent unwanted tampering please see the Setting Lockout information in section 6 5 Program Function Table Generic Programs Program 0 1 2 3 Batt Type Flooded Sealed Flooded Sealed LOAD T erm Functions No Night Light Night Light Low Bat...

Page 18: ...AT2 V 14 0 PWM 1 ALRM V 11 4 SET EVNT Setting for program number Parameter 0 1 2 3 STRT 12 TIME Hr 0 STOP 12 TIME Hr 25 0 EMOD 2 TMOD 0 7 Settings Used in Programs 0 3 When programs 0 3 are selected the PL automatically uses the values below in its regulation The voltage settings are shown correct for 12V operation For higher voltages scale these up eg for a 24V system multiply each voltage figure...

Page 19: ...g Regulation Settings PROG 4 only T o adjust the regulation settings long push on SET short push to REG and long push see figure 7 4A The settings are described below for 12V systems For other voltages the range can be scaled from this eg for a 24V system multiply all voltages by 2 SET REG Submenu Summary 7 4 1 HYST Hysteresis Value When not in PWM mode the PL controls the battery voltage by simpl...

Page 20: ...he full specified time period 7 4 2 Charge Current Limit The PL has a built in charge current limit If the charge current exceeds the CHRG setting the PL will reduce the duty cycle to limit the average charge current This allows the PL 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 m...

Page 21: ...tery PLT PLTB Fig 7 4 3A Attaching a Temperature Sensor to a battery 7 Connecting a Temperature Sensor The temperature sensor should be connected to the T and T terminals in the green terminal block under the lid above the top left corner of the LCD screen The sensor wire with the stripe goes to the T terminal and the sensor wire without the stripe goes to T terminal The wires may be extended if n...

Page 22: ...mance Data to zero 7 7 5 MODE Menu Adjusting Configuration Settings PROG 4 only The MODE submenu contains the settings for the configuration of the PL 7 5 1 7 5 2 LSET GSET There are two configurable output terminals on the PL LOAD and G and six logical functions The LSET and GSET settings define which of the six functions controls each of these output terminals Note that the settings described be...

Page 23: ... PWM 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 disconnect battery 2 Generator control default on when function wants to run generator 3 Generator control off when function wants to run generator 4 Event control on when event is on 5 Event control off when event is on 6 2nd battery cha...

Page 24: ...need to be recalculated if you change either the FLOAT voltage or the EMAX Equalise voltage The function of the dump load is to soak up energy coming in which the battery cannot store in order to maintain the desired battery voltage The input labelled B part of the green terminal block under the cover is intended as a sense input for the battery negative voltage This can be connected directly to t...

Page 25: ...n other wires Fuse Breakers Low current wire Connect close to battery terminals Fig 7 5 3A Battery Sense Input Battery Solar Panel s PL60 80 SOL BAT BAT SOL Load Load B Sense B Sense Fuse Breaker Low Current Wires Connect close to battery terminals NOTE Low Current B Sense wires can be significantly smaller than other wires Fuse Breaker Fuse Breaker Fuse Breaker Fuse Breaker Fig 7 5 3B Battery Sen...

Page 26: ... such as a changeover relay will be required to switch the negative of the solar panel s from the SOL terminal of the PL to the negative terminal on the second battery see fig 7 5 4A You can use either the Load Terminal or G Terminal for switching the relay keep in mind that the G terminal max current is only 120mA for the PL20 and PL40 and 300mA for the PL60 80 A Catch Diode must be fitted across...

Page 27: ... must be taken at higher system voltages particularly 48V because the inductance of the wiring to the photovoltaic panels can 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...

Page 28: ...ush here to set the alarm voltage If the battery voltage falls below the alarm voltage the PL will activate its internal Alarm function it is sampled every 60 seconds If the LSET GSET settings have been configured appropriately this can be used to set off an audible alarm or any Example Battery Low Alarm Output other type of alarm connected to the LOAD or G terminal There is no audible alarm built...

Page 29: ...Sensor operated timed lighting at night Turning on sprinklers for an hour if it s over a certain temperature Using the Event Controller Step 1 Select PROG 4 Many users will not need the event controller so in Programs 0 3 it is automatically disabled For users who do wish to use the event controller Program 4 must be selected Step 2 Set LSET or GSET It is necessary to tell the PL which output term...

Page 30: ...option you must wire a switch or other trigger between the B terminal green terminal block and the BAT terminal and make BSET 2 After setting the STRT value a short push will move you to the setting which goes with that STRT value For example if you set STRT to 1 you will see SOLV Whenever the solar panel voltage drops below the value you set in SOLV the event will start Step 4 Use the STOP settin...

Page 31: ...overrides the Event Controller and your battery will be protected Using settings 8 14 allows the Event Controller to override the Low Battery Disconnect function and your battery will not be protected Note Use TMOD 8 to 14 for any event that controls a charging source via a relay as you do not want the TMOD function being overridden by a low battery condition LBD i e TMOD 0 to 7 will override and ...

Page 32: ...e STRT and STOP conditions If the event is off EOFF the first digit shows the state of the STRT condition 0 inactive 1 active If the event is on E ON the first digit shows the state of the STOP condition In the example above this figure will be 0 during the day i e STRT condition is inactive then 1 at dusk when the solar panel voltage drops to the pre set SOLV value If the battery was fully charge...

Page 33: ...tes due to the STOP and RUN settings EMOD 2 makes sure that this will only happen at night during the day pressing the push button will have no effect Note BSET 2 LSET or GSET 4 3 Pump water if battery is fully charged until tank is full i e switch in tank turns off STRT TIME STOP TIME EMOD TMOD 12 0 5 0 1 0 The STRT condition is always true as the time is always greater than 0 However until the P...

Page 34: ...ter A suitable modem is required for remote communication over a telephone or radio network Remote Display PLM The PL charge controller can be accessed from up to 100m away using a wired remote display All of the functions work in the same way as on the actual controller Includes built in audible alarm and display backlighting The PLM can be used to look at the PL screen in a more convenient or se...

Page 35: ...0 75 V Max voltage G terminal to BAT PL20 PL40 60 V Max voltage between the G relay terminals PL60 PL80 85 V Max voltage B sense to BAT Reads 8V where 8V 0 0V 80 8V 160 10 V Max continuous charge current SOL PL20 20 A PL40 40 A PL60 60 A PL80 80 A Max continuous load current LOAD PL20 20 A PL40 7 A PL60 30 A PL80 40 A Max short term load current a few mins PL20 25 A PL40 10 A PL60 40 A PL80 50 A M...

Page 36: ...NEG B SENSE B SENSE SOL POS BAT POS LOAD POS PUSH BUTTON A A 4 1 Block Diagram of PL20 40 Hardware The PL Controller is designed for common positive installations i e switches solar and load in the negative wire It has a reverse blocking mosfet switch between the SOL terminal and the BAT terminal and a mosfet switch between the LOAD terminal and the BAT terminal There is also a low current mosfet ...

Page 37: ... the limit is due to heating there are many combinations of charge and load current which will produce the same heat level This table shows the limits of some combinations Air temperature aroundthePL C Charge Current Max Load Current Max PL20 PL40 PL60 PL80 PL20 PL40 PL60 PL80 40 C 20 A 40A 60A 80A 20 A 7A 30A 40A 44 20 40 60 80 0 0 30 40 18 37 10 13 20 48 20 0 60 80 30 40 50 18 32 60 80 0 0 30 40...

Page 38: ... Settings LO SET menu settings LOAD menu settings CHRG menu settings AD LINT LEXT L ET LO LON LDEL E T OLT O E O DE L ET ET ET AT A AL ET E NT AX E AX ETI E A ATI LT T TN T TI E OD ON O DEL O EXD N DA ET EXT IN T N T N T T T TO E OD T OD E ET EO EON O E A D ...

Page 39: ...The following data is stored each day at midnight in the History HIST section of the DATA menu 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 ...

Page 40: ... DAY 30 DATA DATA DATA EXIT EXIT IN IN OUT OUT VMAX VMAX DAY 3 DAY 3 DAY 30 DAY 4 DAY 1 SOC BATV Set program CHRG LOAD IN OUT DATA SET Toggle function status on off GRUN GDAY CINT CEXT GSET Set length of generator exercise View change of days since last exercise for run time if generator running LINT LEXT LSET Toggle low battery disconnect status on off INT EXT Clear Clear INT EXT Clear Clear Togg...

Page 41: ... status on off Set voltage at which load disconnects Set voltage at which load reconnects Set delay before switching INT EXT Clear Clear INT EXT Clear Clear Toggle setting lockout A showing means settings adjustable LSET Set function of LOAD terminal GSET Set function of general purpose terminal G BSET Set function of B input BAT2 Set Regulation voltage for 2nd battery control PWM Set which termin...

Page 42: ...Rev 6 3 0 12 09 16 PL Reference Manual 42 A Notes ...

Page 43: ...0 Polycarbonate PL60 Anodised Aluminium PL80 Anodised Aluminium There are two small screws in the sides of the PL60 PL80 These screws are essential for transport Transporting the unit without these screws in place will result in damage which will not be covered under warranty Keep these screws Weight in box PL20 345 grams PL40 560 grams PL60 1154 grams PL80 1154 grams Unit Dimensions PL20 100 x 10...

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