PT-100 Manual

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 qualiﬁ ed electricians and technicians who are familiar with PV

system wiring and safety practices.

WARNING: Dangerous voltages can exist inside the controller. Disconnect all PV and

battery circuits to the PT controller before performing any maintenance or service. The

PT controller has internal capacitors that remain charged after disconnecting all external

sources of power (i.e., PV and battery). Resistors inside the PT controller will remove

this voltage within 5 minutes. Wait at least 5 minutes for these capacitors to discharge

before servicing the unit.

Info: When disconnecting the PT controller, we recommend ﬁ rst disconnecting the

PV array, then the batteries. If the PT controller is charging and the batteries are

disconnected ﬁ rst, you will get a P05 (Power Limited - Above Voltage Regulation) status

and may get a F03 (High PV Input) fault. This is normal and indicates the PV voltage

increased due to the load (i.e., batteries) on the PT controller output being removed.

Normal operation resumes when the battery is reconnected.

5.1 Periodic Maintenance

The PT-100 charge 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 the PT-100 and PV system:

• Inspect and re-torque the wire connections on the charge controller’s internal DC terminal

block and ground busbar connections.

• Check that all communication cable connections are secure.

• Check all conductors for any cracks, breaks, or deterioration in the insulation/conduits.

• Check the ventilation intake screen and exhaust opening, remove any dust/debris that might

have accumulated.

5.1.2 Recommended Battery Care

Batteries are an essential part of the controller/PV system, so they should be regularly and

carefully maintained. It is recommended that every 6 months the following maintenance steps

should be performed to extend their useful life.

WARNING: Prior to performing any checks, switch off any loads on the battery (i.e.,

inverter, DC loads, charge controller).

• Visually inspect the batteries for cracks, leaks, or swelling—replace if necessary.

• Batteries should be clean, dry, and free of electrolyte and corrosion residue. Use baking soda

to clean and remove any electrolyte spills or buildups.

• Clean and tighten all battery terminals and connecting cables.

• Check and ﬁ ll battery water levels (liquid lead acid batteries only).

• Check individual battery voltages (load test those that have a voltage difference of more than

0.3 VDC from each other)—replace if necessary.