PT-100 MPPT Charge Controller Owner’s Manual
Thank you from all of us at Sensata Technologies for purchasing this PT-100 MPPT charge controller. The PT-100 is a product under the Magnum Energy brand from Sensata Technologies. We understand that you have many purchasing options in the marketplace, and we are pleased that you have decided on this product. At Sensata, we are committed to providing you with quality products and services, and hope that your experience with us is pleasant and professional.
Safety Information IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR THE PT-100 MPPT CHARGE CONTROLLER THAT SHALL BE FOLLOWED DURING THE INSTALLATION AND OPERATION OF THIS PRODUCT. Before using the PT-100, read all instructions and cautionary markings. Also, be sure to review the individual manuals provided for each component of the system. The installation instructions are for use by qualified personnel only.
Safety Information Battery Safety/Maintenance CAUTION: The following precautions should be observed when working on batteries: • • • • • • • • • • • • • • • • Do not dispose of batteries in a fire. The batteries may explode. Do not open or damage batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic. Wear eye protection such as safety glasses, and avoid touching your eyes and face when working with batteries.
Safety Information CONSIGNES DE SÉCURITÉ IMPORTANTES CONSERVER CES INSTRUCTIONS CE MANUEL CONTIENT DE IMPORTANTES POUR LA SÉRIE PT-100 ONDULEUR/CHARGEUR QUI DOIVENT ETRE SUIVIES PENDANT L’INSTALLATION ET FONCTIONNEMENT DE CE PRODUIT. Avant d’utiliser la série PT-100, lire toutes les instructions etles mises en garde. Aussi, n’oubliez pas depasser en revue les différents manuels fournispour chaque composant du système. Lesinstructions d’installation sont pour une utilisationpar du personnel qualifié.
Safety Information Sécurité de la pile / Maintenance ATTENTION: Les précautions suivantes doivent être observées lors de travaux sur les batteries: • • • • • • • • • • • • • • • • Ne jetez pas les batteries au feu. Les batteries peuvent exploser. Ne pas ouvrir ou endommager les batteries. L’électrolyte est dangereux pour la peau et les yeux. Il peut être toxique.
Table of Contents Disclaimer of Liability ............................................................................................ i Restrictions on Use ............................................................................................... i Copyright Notice .................................................................................................. i Document Information .......................................................................................... i Contact Information......
Table of Contents (continued) Appendix A – Specifications ................................................................85 Appendix B – Optional Equipment and Accessories .............................88 Appendix C – Charge Controller Terminology ......................................89 Appendix D – PV Conductor and OCPD Sizing Worksheet ....................90 Appendix E – Warranty and Service Information .................................92 E-1 E-2 Limited Warranty ........................................
List of Figures Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 1-1, Front Features ..........................................................................................
Introduction 1.0 Introduction Congratulations on your purchase of the PT-100 Charge Controller. The PT-100 is a Maximum Power Point Tracker (MPPT) charge controller specifically designed to harvest the maximum available energy from the PV array and deliver it to the batteries. The MPPT algorithm in the PT-100 is designed to find the maximum power point of the array and to operate at this point while regulating the output current and battery voltage to fully charge the battery.
Introduction 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 cover ensures maximum durability with minimum weight for more efficient operation.
Introduction The PT controller is equipped with the following features (under the access cover) see Figure 1-2): 4 DIP Switch – this Dual In-line Package (DIP) switch determines the different operating features of the PT Series. See Section 3.0 for information on configuring this switch. 5 ARC Fault Test Button Switch – designed to be a momentary button switch that allows the ARC Fault circuit to be tested. See Section 4.6.1 for information on this switch.
Introduction The sides of the PT-100 charge controller are equipped with the following (Figure 1-3): 16 CE Label – This label means the controller has been tested and conforms to applicable EC directives for emission and immunity—allowing this controller to be sold in Europe. 17 Safety Label – This label provides information to the user to help prevent risk of electric shock, fire, or other safety hazard.
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 qualified electricians and technicians who are familiar with solar system design and wiring practices.
Installation 2.2 PV System Components A simple diagram of a typical stand-alone Photovoltaic (PV) system is illustrated in Figure 2-1. This diagram will help identify the PV system components used with a standalone controller. • PV Array - made up of PV modules and provides DC (solar) power to the PT-100 controller. • PV Strings - an assembly of modules in series that generates DC power at system voltage.
Installation 2.3 2.3.1 Locating and Mounting the PT Controller Removing the Access Cover Before mounting, use a #2 Phillips screwdriver to remove the wiring compartment access cover to expose the mounting holes and wiring terminals. The access cover is secured to the front of the controller with four Phillips #8-32 × 3/8” (9.5 mm) screws as shown in Figure 2-2 below. WARNING: To prevent injury, ensure all PV and battery power to the controller is disconnected before removing the access cover.
Page 8 (3 cm) 3 ” 1 16 B (10.3 cm) 1” 4 16 LEFT SIDE VIEW (3.3 cm) 5” 1 16 5” (12.7 cm) 10 83 ” (26.4 cm) A = 7/8” (22.2 mm) B = 1 23 /64” (34.5 mm) and 1 23/32” (43.7 mm) HOLE DIMENSIONS: KNOCKOUT TRADE SIZES (TOTAL): A = ½” or M20 (x3) B = 1” and 1¼” (x4) Overall dimensions (W x H x D): 8½” x 15⅝” x 4⅛” (21.7 cm x 39.7 cm x 10.5 cm) FRONT VIEW Two dual knockouts inside on wiring box 8 12 ” (21.6 cm) TOP VIEW ” (6.35 mm) 2 holes total 1 4 (39.7 cm) 15 85 ” 5 8 ” B (18.
Installation 2.3.3 Finding a Location The location of the PT controller is important to its performance and operating life. Install it in a location that meets the following requirements: Indoor – The PT controller enclosure is rated for indoor use only. It should be installed in a building or enclosure to protect it from direct rain, sun, wind-blown dust, etc. Cool – This controller should be protected from direct sun exposure or anything that could raise its temperature (e.g., near a heating duct).
Installation 2.3.5 Ventilation and Clearance Requirements The charge controller should not be installed in an area that allows dust, debris, insects or rodents to enter or block the controller’s ventilation openings, or in an area without sufficient air flow around the PT’s enclosure. There must be free air movement through the controller and over the controller’s rear heatsink fins.
Installation 2.3.6 Mounting Methods Two mounting methods are available for the PT-100. The first method allows the controller to be mounted next to a Magnum Panel (i.e., MP or MMP), aligning the conduit openings (see Figure 2-8). The second mounting method uses two brackets on the top and bottom of the controller for mounting directly on a wall, and is normally used in a standalone installation (see Figure 2-10). 2.3.6.
Installation 2.3.6.1.1 Installing the Charge Controller Bracket on a Magnum Panel When a MP or MMP panel is used to mount the PT controller, a bracket is provided to allow the PT controller to be mounted to the side of the panel. This bracket can be easily mounted on either the left or right side of the enclosure. Refer to Figure 2-9 to locate the holes you will use to attach the PT controller to the bracket.
Installation 2.3.6.2 Mounting the Charge Controller on a Vertical Surface The PT controller is shipped with a bracket that consists of two identical plastic pieces. When these two pieces are connected together, they provide a complete wall-mounting bracket that allows the PT-100 to be mounted to a vertical surface (wall)—providing the required minimum 1” (2.5 mm) airflow clearance behind the controller. Refer to Figure 2-13 for bracket dimensions.
Installation 2.3.6.2.2 Mounting the Charge Controller on the Wall-mounting Bracket Once the wall-mounting bracket is securely fastened to the vertical surface, you can now attach the PT charge controller. Refer to Figures 2-11 and 2-12. To mount the charge controller to the wall-mounting bracket: 1. Using two of the #8 Phillips head screws provided, insert the screws into the top two mounting holes of the wall-mounting bracket (designated as “P1” in Figure 2-10).
Installation PT-100 Controller Two-piece wall-mounting bracket 2x4 stud inside wall Figure 2-12, Surface-mounting the PT-100 Controller 7.75" (19.7 cm) 7.19" (18.3 cm) SIDE VIEW 1.13" (2.9 cm) 6.54" (16.6 cm) P FRONT VIEW 6.96" W (17.7 cm) 7.59" (19.3 cm) 6.74" (17.1 cm) 4.75" (12.1 cm) 6.46" 3.56" x2 (16.4 cm) (9.0 cm x2) P 1.75" (4.4 cm) 1.5" (3.8 cm) PT Controller =mounting holes x2 [Ø.120 (3mm) thru hole] W Wall/surface =mounting holes x6 [Ø.180 (43.
Installation 2.4 Electrical System Wiring Diagrams A diagram of the PV and battery wiring for the PT-100 controller is shown in Figure 2-14 and is provided to assist you or your system installer. Due to the variety of applications and differences in local and national electrical codes, this wiring diagram should only be used as a general guideline.
Installation 2.5 PV Voltage Requirements Proper array sizing is crucial to ensure the maximum power output of the PV array is within the PT controller’s MPPT voltage range during normal operating conditions, and to ensure the PV voltage does not exceed the PT-100’s maximum input voltage limit—to prevent damage to the PT-100.
Installation 2.5.2 Determining the Maximum PV Array Voltage In order to size the PV array so that the output voltage never exceeds the maximum PV input voltage limit on the PT-100, the maximum number of modules in series need to be determined. To do this, you must first determine—from the installation location—the VOC of the individual module at the lowest expected temperature.
Installation Examples - Determining the array’s maximum voltage: Using the correct formula (based on which module’s temperature coefficient method is provided) and the values in our scenarios below, first determine the module’s maximum output voltage (VOC-MAX), and then use this value to figure the maximum number of modules that can be connected in series.
Installation 2.5.3 Determining the Upper Output Voltage (VOC-UPP) This section details how to determine the maximum number of modules allowed to be connected in series that will stay below the High VOC range of the PT-100. The Open Circuit Voltage (VOC) of the PV array should normally operate below the High VOC range of the PT-100, (which is also the upper limit of the MMPT voltage range). The PT-100 will stop operating if the voltage is allowed to rise into the High VOC range.
Installation 2.5.4 Determining the Lower Maximum Power Voltage (VMP-LOW) Lastly, you must ensure the maximum power voltage (VMP) of the individual module at the lowest expected temperature does not fall below the controller’s lower MPPT voltage limit. When determining the number of modules in series, the VMP of the modules connected in series should normally operate within the MMPT voltage range of the PT-100; thereby, maximizing the energy output of the PV system.
Installation 3B) Calculating Minimum Number of Modules in Series for Lower VMP: After calculating the module’s lower VMP-LOW level, determine the minimum number of modules that can be placed in series. Refer to Table 2-1 to find the PT-100’s lower MPPT voltage limit based on the particular battery bank connected to the PT-100. Once the controller’s lower MPPT voltage limit has been determined, divide this value by the VMP-LOW calculation and round up to the nearest whole number.
Installation 2.6 Conductor Sizing for the PV System It is important to use the correct sized DC wire (or conductor) in a Standalone PV System (includes PV, controller and standalone inverter) to achieve maximum system efficiency and to reduce fire hazards associated with overheating. The NEC (Section 690) provides the requirements for proper conductor sizing and current calculations for PV systems.
Installation 2.6.2 Select the Correct Conductor To properly determine the required ampacity of the conductors in the PV System circuits, the NEC requires a comparison of conductors that are sized with different adjustment factors. A conductor sized to continuously carry the maximum current is calculated and compared against a conductor sized with conditions-of-use factors applied.
Installation Check the Terminal Temperature Rating - Whether the conductor is sized to continuously carry the maximum current or sized with conditions-of-use factors applied, the temperature rating associated with the ampacity of a conductor must be coordinated so as not to exceed the lowest temperature rating of any terminal, device, or conductor of the circuit.
Installation 2.6.3 Sizing the DC OverCurrent Protection Device (OCPD) The final step necessary in sizing the DC conductor is to verify that the selected conductor can handle the current and is protected by the DC OverCurrent Protection Device (OCPD). Once you have identified the conductor that will handle the maximum continuous current (described in Section 2.6.
Installation 2.6.4 Steps to Sizing Conductors and Overcurrent Protection in a PV System Info: A worksheet to help size PV conductors and overcurrent protection devices using the following steps is provided in Appendix D. Info: Tables referenced in this section are from the 2014 Edition of the National Electrical Code® (also known as NFPA 70). To calculate the required conductor and the overcurrent protection device size, follow these steps: Step 1 - Calculate the maximum current for the circuits (IMAX).
Installation 2.6.4.1 Example to Determine the Size of the PV System Conductors and OCPD’s Find the PV System conductors and OCPD size: Scenario: The PV system will be installed in an area where the average high temperature is 26°C. The array has three PV strings (six current-carrying conductors), these source conductors are bundled together and connect to a fused string combiner. The lowest temperature rating of any terminal is 75°C. The modules have a short circuit current rating (ISC) of 6.
Installation Find the PV System conductors and OCPD size (continued): Continued Scenario: The PV output conductors of the combiner (two current-carrying conductors) run through conduit 2” above the rooftop and connect to a PV disconnect breaker installed in an MMP enclosure with a PT-100 charge controller. The lowest temperature rating of any terminal is 75°C. B) Find the PV Output circuit conductor and OCPD size: Step 1 - Calculate the maximum current for the PV output circuits (IMAX).
Installation Table 2-2, Allowable Conductor Ampacities The table below shows the allowable ampacities of insulated copper conductors rated 0 through 2000 volts, 60°C through 90°C, not more than three current-carrying conductors in a raceway, cable, or earth (directly buried), based on ambient temperature of 30°C (86°F).
Installation Table 2-4, Rooftop Distance Adjustments Distance Above Roof to Bottom of Raceway or Cable Temperature Adder 0 to 13 mm (0 to ½ in.) Greater than 13 mm (½ in.) to 90 mm (3½ in.) Greater than 300 mm (12 in.) to 900 mm (36 in.) (°C) (°F) 33 28 14 60 50 25 Data taken from Table 310.
Installation 2.7 Wiring the PT-100 This section describes the requirements and recommendations for wiring the PT charge controller. The NEC (National Electric Code, ANSI/NFPA 70) for the United States and the CEC (Canadian Electrical Code) for Canada provide the standards for safely wiring residential and commercial installations. WARNING: Wiring to the PT charge controller should meet all local codes and standards and be performed by qualified personnel such as a licensed electrician.
Installation 2.7.
Installation 2.7.4 PT-100 Output Conductor Size It is important to use the correct sized DC wire to achieve maximum efficiency from the system and to reduce fire hazards associated with overheating. Always keep your wire runs as short as practical. For correctly sizing the PV source and PV output conductors (and corresponding overcurrent device) see Section 2.6.
Installation 2.7.6 Equipment Grounding Conductor The PT controller case and all other noncurrent-carrying exposed metal surfaces in the entire electrical system that may be accidentally energized must be grounded. The equipment-grounding conductor must be sized to safely carry the maximum ground-fault current likely to be imposed on it from where a ground-fault may occur. In accordance with the NEC, use Table 2-9 to size the equipment-grounding conductors.
Installation 2.7.7 Wiring for the Internal GFDI The PT-100 charge controller is equipped with GFDI (Ground Fault Detection/Interruption) capability and the normal factory default is with the GFDI feature enabled (DIP switch 2 is down). With the GFDI enabled, the PV negative and battery negative lines must be wired so that they are floating with respect to ground—the single point of ground for the DC system is made within the PT controller through its internal 0.5-amp GFDI fuse.
Installation 2.7.8 Terminal Block Connections The charge controller provides a four-pole, high power (125 amps), 600-volt rated, DC terminal block and a ground busbar to connect the PV input and battery output wires. Each connection on the terminal block is rated up to 75°C and can accept one #20 to 1 AWG (0.5 to 42.4 mm2) wire. Use a #2 Phillips head screwdriver to tighten each connection to a recommended tightening torque of 30 in lbf (3.4 N-m).
Installation 2.7.9 Steps to Wiring the PT-100 The following steps are basic guidelines for connecting PV and battery wiring to and from the PT100 charge controller. Remove the four Phillips screws on the wiring access cover to access the terminal block (see Figure 2-2). Refer to Figure 2-17 while making the connections.
Installation 2.8 Wiring the Battery Temperature Sensor The Battery Temperature Sensor (BTS) shown in Figure 2-18, allows the charge controller to automatically adjust the charge voltage set-points to correctly charge the batteries under extreme temperature changes. If the temperature sensor is NOT installed and the batteries are subjected to large temperature changes, the life of the battery may be shortened.
Installation 2.9 Wiring the Auxiliary Relay The PT controller contains an internal auxiliary (aux) relay used to turn an external DC device on or off. The aux relay is wired through an on-board 3-port connector (see Figure 1-2, Item 7). When the PT controller is configured as a standalone controller, this aux relay only engages when there is a controller fault. When the PT-100 is networked to a Magnum inverter and using a Version 4.
Installation 2.10 Network Wiring 2.10.1 Communications Cables - Provided The NEC/CEC requires the insulation of all conductors inside the PT controller to be rated for the highest voltage present. The PT controller is designed to work with voltages up to 240 volts, therefore, the voltage rating of the communications cables inside the MP enclosure must be rated for 240 volts or higher to be code compliant.
Installation 2.10.2 Connecting the Network Cable One end of the network cable plugs into the NETWORK (green) port on the PT controller, and the other end plugs into the NETWORK (green) port on the Magnum inverter/charger (see Figure 2-24). Note: The network cable can be extended up to a length of 200 feet without data degradation; however, the PT controller and inverter must be connected to the same battery bank. Note: If you are installing additional accessories (e.g.
Installation Networking the PT-100 the with PT-100 Other Network Devices Chain Configuration) Networking (Daisy Chain(Daisy Configuration) Magnum Inverter/charger ME-ARC PT-100 (CHARGE CONTROLLER) (ADVANCED REMOTE) ME-BMK (BATTERY MONITOR) ME-AGS-N (NETWORK AGS) 2-way Phone-splitter 2-way Phone-splitter Note: TheME-AGS-N ME-AGS-N or PT-100 must benetwork the first network device to the inverter, Note: The or PT-100 must be the first device connected to theconnected inverter, followed by the ME-BMK, fol
Installation Networking the PT-100 with Network (Star Configuration usingsplitters) two 2-way splitters) Networking the Other PT-100 (StarDevices Configuration using 2-way ME-ARC Magnum Inverter/charger PT-100 (CHARGE CONTROLLER) (ADVANCED REMOTE) Two 2-way Phone-splitters ME-BMK (BATTERY MONITOR) ME-AGS-N (NETWORK AGS) Networking the PT-100 (Star Confi guration using a 3-way Networking the PT-100 with Other Network Devices (Star Configuration usingsplitter) a 3-way splitter) ME-ARC Magnum Inverter/c
Installation 2.11 Stacking Installation - Wiring Multiple PT Controllers Together A single PT controller can provide up to 100 amps of charging current to the battery bank. When more charging current is required than can be provided by a single PT controller, up to seven PT controllers can be connected (or “stacked”) together to increase the charge current capability.
Installation Stacking with Ground Fault Protection If the PT controller’s internal Ground Fault Detection and Interruption (GFDI) feature is being used—rather than an external GFDI device—in a multiple controller installation, the following requirements must be met to ensure the GFDI circuit works properly. • All PT controllers stacked together must have DIP switch 2 in the DOWN position (GFDI enabled).
Installation WIRING LEGEND PV DC GROUND PV ARRAY PV NEGATIVE (-) PV ARRAY PV PT-100 Controller (Master) POSITIVE (+) PV PT-100 Controller (Slave 1) PV PV ARRAY PV PT-100 Controller (Slave 2) Magnum Remote REMOTE Cable (300V) To PT-100 Master Controlle r 123456789 Int ernal GFDI fuse 123456789 123456789 NETWORK Cable (300V) Magnum Inverter INVERTER DC DISCONNECT BTS Ex tension Cable (300V) BTS DC Shunt TO PRIMARY DC GROUND SYSTEM .BATTERY TEMP SENSOR B . B .
Page 48 REMO TE REMOTE Cable REMO TE BTS Cable NETWORK Cable BTS to Battery Bank NETWORK Magnum Inverter (front view) NETWORK 2" min STACK Cable Stack Address (C02) Stack Mode (Enabled) 1 2345 6789 Slave 1 PT Controller (address = C02) 2" min 123456789 NETWORK Slave 2 PT Controller (address = C03) Stack Address (C03) Stack Mode (Enabled) STACK Cable Figure 2-28, Networking Multiple PT Controller’s Stack Address (C01) Stack Mode (Enabled) 123456789 Master PT Controller (address = C01)
BTS to Battery Bank BTS Cable STACK MS SL1 SL2 SL3 REMO TE REMO TE NETWORK Cable (to NETWORK port on one of the inverters and to NETWORK port on Master PT-100) Stack Address (C01) Stack Mode (Enabled) 123456789 NETWORK Master PT Controller (address = C01) . 2" min .
Installation 2.12 Final Inspection/Tests 1. Verify all cables/conduit runs are secured, and verify strain reliefs or grommets are in place to prevent damage to the wiring or conduit where it passes through walls or other openings. 2. Ensure that all conduit connections are clean and tight, and are properly sealed against any environmental concerns. 3. Verify all DC connections (battery and PV) are correct and torqued properly. 4.
Installation 2.12.2 Power-up Test When the controller is connected to DC power (either PV or battery), a diagnostic power-up test is performed (refer to Figure 2-30). This power-up test takes approximately 12 seconds to complete and verifies that all of the front panel LED’s and the display come on and stay on until the test is complete.
Setup 3.0 Setup When the PT controller is not connected to a Magnum inverter/remote, the internal DIP switch (Figure 1-2, Item 4) is used to determine the PT controller’s operation. Info: When the PT controller is connected and networked with a Magnum 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.
Setup Switches 3 & 4: System’s Battery Voltage Four (4) settings are available for your system’s nominal battery voltage as shown below. Use the auto voltage detection setting (default) to determine the system voltage automatically when the battery is connected to the PT controller; or, if the battery is out of its nominal voltage range (i.e., highly discharged), select the setting that matches the system’s nominal battery voltage.
Setup Switches 7, 8 & 9: When DIP switch 10 is in the (normally) DOWN position, DIP switches 7, 8, and 9 determine the absorption charge time of the PT controller. However, if DIP switch 10 is set to the UP position, it enables Stack mode and allows the PT controller to be networked (i.e., connected to a Magnum inverter and remote).
Setup Table 3-2, Summary of DIP Switch Position UP DEFAULT SETTING (all switches down) DOWN (DN) Switch Function SW1 ARC Fault Detection SW2 Ground Fault Detection SW3, SW4 SW5, SW6 System Voltage Battery Type Stack address switches* Absorption Time SW7, SW8, SW9 SW10 (controller address number when stacked) Stack Mode Switch Position Enabled SW1 DN Disabled SW1 UP Enabled SW2 DN Disabled SW2 UP Auto Detect SW3 DN SW4 DN 12V System SW3 DN SW4 UP 24V System SW3 UP SW4 UP 48
Operation 4.0 Operation This section explains how the controller operates, and also provides information on the LED indicators and the digital display that are used to show the operational status of the PT controller. 3-Character Display with LED Indicators PT Fault LED Indicator Charge Status LED Indicators AUX Relay LED Indicator SELECT Pushbutton RESET Pushbutton Figure 4-1, Front Panel Display and LED Indicators 4.
Operation 4.2 Front Panel Operation When power is applied, the display on the PT controller goes through a power-up test routine (see Figure 2-30). Once the power-up test is complete and no faults occur, the controller begins operating and the display begins automatically scrolling through the operational displays (see Figure 4-2). 4.2.
Operation 4.2.2 Charge Status Indicators The charge status LED indicators on the front panel indicate the charge status of the controller. The table below describes the charge stage of the controller and the charger operation—depending on what the charge status LED’s are doing.
Operation 4.2.3 Power Status Codes The digital display shows a P-number (P##) to indicate the status of the PV power delivered to the battery—through the controller. Table 4-2 lists each Power Status Code and its description. Info: If the display is auto-scrolling, the power status only shows if the power output is being limited (P03 - P05), otherwise only the first four operational displays will be seen.
Operation 4.2.4 Fault Indicator Whenever a fault condition occurs, the red FAULT indicator illuminates (comes on or blinks) and a fault code (F##) is displayed. Info: If a fault code (F##) is displayed, refer to Section 5.3 to determine and troubleshoot the fault condition. Hard Faults - If the fault condition causes the controller to shut down, the fault indicator will be on solid (see Figure 4-4). These are referred to as hard faults (F01 - F04, F06 - F09, F11 - F16).
Operation 4.2.6 • • • • • • • • • • • • Display/LED Indicator Summary PV VOLTS (green) is ON = displays the input voltage from the PV array. PV KW (green) is ON = displays the PV array power (in kilo-watts) to the battery bank. Battery VOLTS (green) is ON = displays the voltage of the battery bank. Battery AMPS (green) is ON = displays the current going into the battery bank. BULK (blue) is ON = the controller is in the Bulk charge mode.
Operation 4.3 MPPT Operation The PT-100 charge controller uses Maximum Power Point Tracking (MPPT) to harvest the maximum possible power from the PV array—under any environmental condition—to charge the batteries. The purpose of MPPT is find the point of the PV array’s operating curve (shown in Figure 4-8) where the current (I) and voltage (V) are optimized at the same time—referred to as the Maximum Power Point (MPP).
Operation 4.4 Charger Control Operation As a charge controller, the PT-100’s primary function is to monitor and charge the batteries appropriately when PV power is available, and to prevent the batteries from being overcharged. When PV power is connected to the PV input, the charge controller begins monitoring for acceptable PV power and begins charging the batteries once it has accepted the PV input.
Operation 4.4.1 Equalizing the Battery Bank Equalizing (EQ) is a “controlled overcharge” of a lead-acid battery (or battery bank) done to help the battery reach and maintain peak capacity. This controlled overcharging helps equalize the chemistry in the individual battery cells by mixing the battery electrolyte (to reverse the buildup of stratification), and by removing lead sulfate that may have built up on the plates. These conditions if left unchecked, reduce the overall capacity of the battery.
Operation 4.4.2 Starting or Stopping an Equalization Charge Cycle See Table 3-1 to determine the equalize voltage for your battery type. Equalize charging can only be enabled if the Battery Type setting allows. Info: Equalization charging is available if FLOODED or AGM 1 is selected as the Battery Type (DIP switches 5 and 6), it is not available if GEL or AGM 2 is selected. To start the equalization charge cycle: 1.
Operation 4.6 Arc-Fault Protection Operation Arcs are caused by an intermittent connection and are dangerous because they are not an overload or short-circuit, so the overcurrent protective device does not operate; however, they can burn through wiring insulation or ignite nearby combustibles. The PT controller has an integrated Arc-Fault Protection (AFP) circuit, which provides additional protection against fires caused by an arc in the PV system.
Operation 4.7 Battery Temperature Sensor Operation The plug-in Battery Temperature Sensor (BTS) is used to determine the battery’s temperature. This information allows the multi-stage battery charger to automatically adjust the battery charge voltages for optimum charging performance and longer battery life. With a BTS installed, the controller will adjust the absorb and float charge voltages according to the temperature around the BTS.
Operation 4.8 Charge Controller Fan Operation The charge controller contains two internal cooling fans that are automatically controlled. When the fans turn on or turn off is determined by the temperature of certain components inside the charge controller. The charge controller’s fans will come on under the conditions listed below.
Operation 4.10 Auxiliary Relay Operation When the PT controller is configured as a standalone device (i.e., not networked with a Magnum inverter/remote), the internal aux relay stays disengaged during normal operation, but engages when a PT controller fault is detected. If the PT controller is networked (i.e.
Operation 4.12 Operating Configuration - Standalone vs Networked The operating configuration in the PT-100 controller uses default settings that are adequate for most installations (shown in Table 4-3 and described below). When the controller is configured as a standalone controller, the controller’s internal DIP switch is used to adjust these settings.
Operation 4.13 Stacking Operation This section provides information on how to identify stacked controllers, and how they communicate between each other and with the network remote. 4.13.1 Viewing the Controllers Network Address - Stacked Configuration When multiple PT controllers are connected/networked together in a stacked configuration, the controller configured with the lowest network address from C01 to C07 is the master controller.
Operation 4.13.2 Network Communication between each Stacked Controller When multiple PT controllers are networked together in a stacked configuration per Section 2.11 (Stacking Installation - Wiring Multiple PT Controllers Together), they operate as listed below: 1. The controller configured with the lowest network address (using DIP switches 7, 8, and 9) is the master controller and all other controllers networked together become slave controllers (and therefore follow the master).
Operation • PT Tech Menus a. PT Temperatures: • PT BTS - Shows the temperature of the BTS which is used for battery charging temperature compensation (refer to Section 4.7). Note: If there is more than one BTS connected, then in order of priority, the BTS on the inverter is used first; then the BTS with the lowest address (i.e., master controller); then the controller with the next lowest address (i.e., slave controller). • PT FETs - Highest FET temperature from any of the stacked controllers.
Maintenance and Troubleshooting 5.0 Maintenance and Troubleshooting This section contains an overview of maintenance recommendations and troubleshooting information for the PT-100 controller. WARNING: Performing service or maintenance on the controller can be life-threatening if done improperly. Service on the controller must only be performed by authorized personnel, these are qualified electricians and technicians who are familiar with PV system wiring and safety practices.
Maintenance and Troubleshooting 5.2 Basic Troubleshooting The PT-100 charge controller is a fairly simple device to troubleshoot. The following chart is designed to help you quickly pinpoint the most common charge controller failures. If a fault code (F##) is shown on the display, refer to Sections 5.3 and 5.4. Table 5-1, Basic Controller Troubleshooting (Remote not available) Symptom Possible Cause No display and all Battery voltage and PV voltage is too low. LEDs are off.
Maintenance and Troubleshooting FAULT LED ON High PV Input Fault - The PT controller turned off and stopped producing power to the batteries because a very high PV voltage (>187 VDC) has been detected on the PV input terminals (i.e., PV+ to PV-). This is usually caused during cold weather if the PV array voltage is sized too high or too close to the maximum PT input operating voltage.
Maintenance and Troubleshooting FAULT LED ON High Battery Temp Fault - The PT controller turned off because the temperature around the BTS has reached a temperature greater than 54°C/129°F. Remedy: Check the area where the BTS is located; if placed on a battery, ensure the connection to the battery terminal is tight, that the batteries are not overheated, or that the BTS hasn’t been placed in a hot area or near a hot device. If neither of these are the issue, then remove the BTS from the BTS port.
Maintenance and Troubleshooting FAULT LED ON FAULT LED ON FAULT LED ON FAULT LED ON FAULT LED ON GFDI Fault - The GFDI fuse in the PT controller has opened due to a ground-fault condition. Note: If the GFDI detection is not required, set DIP switch 2 to UP. Remedy: Correct the ground-fault condition and replace the fuse (see Section 5.5). Once this is done, press the RESET pushbutton for one second to clear the fault and turn the controller on.
Maintenance and Troubleshooting 5.4 Stacking Fault Codes When multiple PT controllers are connected together in a stacked configuration, additional fault conditions can be detected and will appear in the digital display to identify the problem. The following table describes each fault code (F2#) and any corrective actions to be taken for each code.
Maintenance and Troubleshooting Table 5-3, Stack Fault Code Descriptions (continued) Stack Switch Fault - The PT controller is not able to run because the controller’s stacking address has been incorrectly set. Remedy: 1. Ensure the stacking address is not set to C00. FAULT LED ON a. C00 is an invalid stacking address, examine DIP switches 7, 8, and 9 to ensure that only C01-C07 is set as the stacking address (see Section 3-1, Switches 7, 8 & 9). 2.
Maintenance and Troubleshooting 5.5 Removing/Replacing the GFDI Fuse WARNING: Dangerous voltages can exist inside the controller. Disconnect all PV and battery circuits to the PT controller before removing or installing the GFDI fuse. The PT controller has internal capacitors that remain charged after disconnecting all sources of power. Wait at least 5 minutes for these capacitors to discharge before servicing the unit.
Maintenance and Troubleshooting 5.6 Removing and Replacing the Electronics Section The PT controller is designed as a two-piece unit, with a repairable upper electronics section physically connected to a lower non-serviceable wiring/conduit box—making it easier to service. This allows any wiring/conduit connected to the PT controller to remain in place, while the electronics section is easily removed and replaced if service is required.
Maintenance and Troubleshooting 5.7 Resetting the PT-100 Charge Controller Certain conditions—such as clearing an internal fault—require that the PT-100 be reset. Most times a software reset (also known as a soft reset) is sufficient, otherwise a power reset is (also known as a hard reset) is required. 5.7.1 Performing a Software Reset (AKA Soft Reset) To perform a software reset (also known as a soft reset): 1. Remove all PV power to the PT controller—normally done by opening the PV input breaker. 2.
Maintenance and Troubleshooting 5.8 Updating the PT-100’s Firmware Firmware updates for the PT-100 are provided to improve performance, fix issues, and to add new features or change functionality. Firmware updates are periodically available for download on our website (www.SensataPower.com). This website also provides an Instruction Sheet that gives a detailed step-by-step procedure for successfully downloading and installing the update.
Appendix A – Specifications Appendix A – Specifications A-1 PT-100 Charge Controller Specifications Electrical Specifications Maximum PV Input Voltage (any condition) PV Operating Voltage Maximum Input Current Nominal Battery Voltage Options Battery Charger Output Voltage Range Continuous Charger Output Current Maximum Output Power Peak (and Full Power) Efficiency Tare Loss/Night-time Power Consumption Charger Regulation Method 200VDC + battery voltage or 240VDC –whichever is lower (VBat + 8V) to 187 VD
Appendix A – Specifications A-2 Performance Graphs A-2.1 Ambient Temperature verses Continuous Current As the temperature of the power devices inside the PT-100 increases, the maximum allowable charger current is reduced. The following curve shows the effect of charger current with the temperature above 40°C.
Appendix A – Specifications A-2.3 Maximum Power verses MPP 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. PT-100 vs Competition Maximum Power vs MPP Voltage Maximum Power, Kw 7 6.5 6 5.5 5 4.
Appendix B – Optional Equipment Appendix B – Optional Equipment and Accessories The following components are available for use with the PT-100 Series charge controller. Some of these items are required. Depending upon the intended use of the charge controller. Standard Remote Control (ME-RC) The ME-RC remote control panel uses an LCD screen and at-a-glance LED’s to provide operating information; also provides monitoring, troubleshooting, and feature configuration.
Appendix C – Terminology Appendix C – Charge Controller Terminology The following is a glossary of terms with which you may not be familiar. They appear in the various descriptions of charge controller and battery charger operation. Absorption Stage – In this second stage of three stage charging, the batteries are held at a constant voltage (the absorb voltage setting) and the battery is charged to its maximum capacity.
Appendix D – Sizing Worksheet Appendix D – PV Conductor and OCPD Sizing Worksheet Battery Bank Battery Breaker . 2 1 . PV Source . PV Output PV Circuits: PV Source [1] 1 and PV Output [2] 2 . . 3 PV Controller (PT-100) Output Circuit Inverter AC Panel Inverter/ Charger Battery Breaker 4 . .
Appendix D – Sizing Worksheet b) Find the PV circuit’s conductor size after derating factors have been applied: Look at Table 310.15(B)(16) and select the insulation temperature rating column that corresponds to the lowest temperature rating of any terminal the conductor is terminated on, regardless of the insulation of the selected conductor. Select the smallest conductor that exceeds the derated current (IDERATE) calculation from Step 3a.
Appendix E – Warranty & Service Information Appendix E – Warranty and Service Information E-1 Limited Warranty Sensata Technologies warrants the PT-100 to be free from defects in material and workmanship that may result in product failure during normal usage, according to the following terms and conditions: 1. The limited warranty for the product extends for 60 months beginning from the product’s original date of purchase. 2.
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