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PHOTOVOLTAIC POWER CONTROL

(

PPC

)

Photovoltaic Battery Charge Controller

Installation And Operation Manual

SPECIALTY CONCEPTS, INC.

8954 Mason Ave.

Chatsworth, CA 91311 USA

MODELS: PPC-12, PPC-24, PPC-36, PPC-48 Copyright 8 / 1996 Specialty Concepts, Inc.

GENERAL DESCRIPTION

The Photovoltaic Power Control (PPC) is a versatile, industrial quality charge controller for the

efficient use of photovoltaic energy and the protection of expensive batteries. It is available for

12, 24, 36, and 48 volt negative ground systems with models for 30 amps of charge current

(optional 50 amps available) .

The PPC consists of a series-relay battery charge controller in a wall mount enclosure with

low- voltage load disconnect, a load circuit breaker, array fuse, metering and system status

lights. The lights indicate "CHARGE MODE" and "LOAD DISCONNECT" conditions and the

meters monitor battery voltage and charging current, providing system status and information.

FEATURES

CHARGE REGULATION

• 30 amp charge current, 12, 24, 36 or 48 volt

• 50 amp charge current available (P option) for

12 and 24 volt units

• Two-step, series charging, 12,24 v

• Single step, series charging, 36,48 v

• Adjustable charging set-points

• Temperature compensation

LOW-VOLTAGE LOAD DISCONNECT (LVD)

• 30 amp LVD, 12 volt

• 20 amp LVD, 24 volt

• 15 amp LVD, 36 and 48 volt

• Adjustable disconnect set-points

• Manual override switch

DESIGN FEATURES

• Maximum array usage

• Over-current protection: Array fuse (30 amp

units)

• Over-current protection: Load circuit breaker

• Reverse polarity protection

• Reverse leakage protection

• Lightning protection

• Input noise suppression

• Remote battery voltage sense

MONITORING / MOUNTING

• Analog volt / amp meter

• Charging light

• Load disconnected light

• Indoor wall mount enclosure

• Outdoor enclosure (optional)

Summary of content (21 pages)

PAGE 1
PHOTOVOLTAIC POWER CONTROL (PPC) Photovoltaic Battery Charge Controller Installation And Operation Manual SPECIALTY CONCEPTS, INC. 8954 Mason Ave. Chatsworth, CA 91311 USA MODELS: PPC-12, PPC-24, PPC-36, PPC-48 Copyright 8 / 1996 Specialty Concepts, Inc. GENERAL DESCRIPTION The Photovoltaic Power Control (PPC) is a versatile, industrial quality charge controller for the efficient use of photovoltaic energy and the protection of expensive batteries.
PAGE 2
SPECIFICATIONS PARAMETERS UNITS NOMINAL VOLTAGES 12 v Charge Current, Continuous (1) (Amps) 30 Charge Current, Max (60 seconds) (2) (Amps) 39 Load Current, Continuous (3) (Amps) 30 Load Current, Max (60 seconds) (4) (Amps) 39 Array Voltage, Max Voc (Volts) 22 Operating Voltage @ Battery, Minimum (Volts) 8.5 Quiescent Current (5) (Milliamps) 10 Current Consumption, Charging (6) (Milliamps) 160 Current Consumption, Load Disconnected (7) (Milliamps) 140 Voltage Drop, Typ.
PAGE 3
RELATED SYSTEM EQUIPMENT The PPC is an integral part of a solar electric power system that includes a PV solar array, a battery and a load. These items should be installed in accordance with the National Electrical Code, and with the instructions provided by the equipment supplier.
PAGE 4
INSTALLATION WARNINGS / CAUTIONS WARNING : Electricity, even low voltage electricity, can be dangerous. Installation should be performed by a licensed electrical contractor or other qualified personnel only. It is recommended that the requirements of the U.S. National Electrical Code be followed. WARNING : Follow all battery safety precautions of the battery manufacturer and the National Electrical Code. Proper ventilation must be provided for vented batteries.
PAGE 5
INSTALLATION INSTRUCTIONS: 1. LOCATION: - A suitable location must be found for mounting the PPC. The unit should be mounted on a vertical surface and be as close as possible to the batteries to avoid errors in battery voltage reading. The temperature sensor wire is 10 feet long and should reach the battery bank if possible. 2. PROTECTION REQUIREMENTS: - The unit should not be placed in direct sunlight or close to any heat generating source to avoid extreme temperature increases.
PAGE 6
9. NOTE WIRE POLARITY: - Insure that the polarity of the wires is correctly marked, using colored wires or tags. Incorrect polarity should not damage the PPC, but incorrect operation would result. 10. COMPLETE ARRAY AND BATTERY CONNECTIONS: - Connections to the PPC terminal block should be made with just the bare wire (not crimped spade or ring lugs unless the lugs are crimped AND soldered) 11. COMPLETE LOAD CONNECTIONS: - Refer to wiring diagram (FIGURE 1).
PAGE 7
POWER CONNECT SEQUENCE It is recommended that the power is supplied to the system using this sequence. Some of the circuits within the PPC must be reset to their "start state" and this is automatically accomplished if the power is supplied in this order. If the order is not followed, a period of up to 24 hours may have to elapse before the electronics are fully reset.
PAGE 8
FIGURE 1 PHOTOVOLTAIC POWER CONTROL SOLAR ARRAY + PPC Temp. Comp. A B + BATTERY Jumpers: These jumpers (2) should remain as shown unless a Battery Voltage Sense Connection is needed. See INSTALLATION INSTRUCTIONS: BATTERY VOLTAGE SENSE CONNECTION + LOAD + DC LOAD CENTER (OR) INVERTER / CHARGER (OR) GENERATOR / ALTERNATOR Note: This connection from the load can be wired to the PPC directly for low-voltage load disconnect (as shown) or the load can connect directly to the battery.
PAGE 9
TEMPERATURE COMPENSATION DESCRIPTION: - The PPC has a small sensor on a ten foot cable that is wired into the control to adjust the charging thresholds according to battery temperature. The rate of compensation is -5mv/°C per battery cell in series from 25° C.
PAGE 10
SETTINGS / ADJUSTMENTS ADJUSTABLE CHARGE TERMINATION SET-POINTS - (“Charge Set-Point”): Four different charge termination voltage set-points are available with this switch. The control is factory set at position B. To change the set-point, locate the adjustment switch on the front panel. Using a slotted screwdriver, turn the switch until the slot is pointing at the desired position. If problems develop, refer to the "TROUBLE SHOOTING" section of this book.
PAGE 11
OPERATION CHARGE REGULATION (12 and 24 volt units): The two-step control circuit regulates the charging of storage batteries by monitoring battery and solar panel voltage. STEP 1: CONSTANT CURRENT (FULL) CHARGE MODE: At sunrise, the charging relay energizes and closes, connecting the solar panel directly to the battery and lighting the "CHARGE MODE" light. The battery will accept as much current as the solar panel will provide, and battery voltage will rise.
PAGE 12
results in the relay being open every night. Note: The relay may be closed ("Charging" light on) for a few hours in the evening after the sun has gone down.
PAGE 13
MONITORING "CHARGE MODE" LIGHT: The "Charge Mode" light will be on when the controller is in the full charge mode. In this mode, the charging relay is closed, connecting the array directly to the battery. This light should go on first thing in the morning, and will go off if the battery reaches the "Full Charge Termination" set-point. If the light is off after morning, the batteries have reached the full charge voltage some time that day.
PAGE 14
FUSE / CIRCUIT BREAKER “ARRAY FUSE” - An array fuse is included for the 30 amp PPC. (Not available on 50 amp units (Option P)). This will protect the controller from over-current from the solar panels or a short circuit at the array. Replacement is a 30 amp AGC fuse. “LOAD PROTECTOR” - A load circuit breaker is included with the PPC. This provides overcurrent protection for the load circuit (PPC and load connections) and provides protection from a short circuit at the load.
PAGE 15
TROUBLE SHOOTING: GENERAL NOTES IF THE CONTROLLER IS NEWLY INSTALLED, CHECK THESE THINGS FIRST: 1) Re-check system wiring to insure proper installation and polarity . 2) Check all system fuses and circuit breakers. Before replacing a blown fuse, locate and correct the cause. 3) Check to be sure that there is a connection (voltage input) to the "BATTERY SENSE" terminals from the battery.
PAGE 16
PROBLEM DESCRIPTIONS BATTERY UNDER CHARGED CONTROLLER NOT CHARGING AT ALL, ALWAYS IN THE FLOAT MODE ("CHARGE MODE" LIGHT OFF) Check to see that the controller is receiving voltage (at least about nominal system voltage) from the battery and the solar panels. If it is, momentarily disconnect and reconnect the panels, using an array disconnect switch (if included with your system). The controller should reset into the full charge mode ("CHARGE MODE" light on).
PAGE 17
installation or if the array has been manually disconnected that day. If the light stays on all night every night, the timer may be defective. BATTERY OVERCHARGING CONTROLLER ALWAYS IN FULL CHARGE ("CHARGE MODE" LIGHT ON) See General Note #6 above: The battery may not be reaching the charge termination set-point. See General Note #3 above: No voltage at the battery sense terminals tells the controller that the battery voltage is low and needs to be charged more.
PAGE 18
Check the load circuit breaker on the front of the controller. If the breaker is tripped, the load will not operate.
PAGE 19
FIELD TEST PROCEDURE: PPC Test equipment required: Digital Multimeter Conditions: Sunny or bright overcast if possible This procedure assumes that the solar panels are installed and operational and capable of producing at least 17.5 volts open circuit (for a 12 volt system). Proportionately higher for higher voltage systems. Systems should be equipped with disconnects or switches to facilitate connecting and disconnecting the batteries and solar panel as described in this procedure.
PAGE 20
BENCH TEST PROCEDURE: PPC Test equipment required: Digital Multimeter, Adjustable Power supply Nominal Voltage 12 24 36 48 Power Supply Range 10-18 Vdc 20-36 Vdc 30-48 Vdc 40-64 Vdc All measurements described in this procedure should be made at the controller terminals. 1) Make sure that there is a jumper between Battery(+) and Battery Voltage Sense(+) and one between Battery(-) and Battery Voltage Sense(-). 2) Check continuity between Battery(-),Solar Panel(-) and Load(-).
PAGE 21
LIMITED FIVE YEAR WARRANTY SPECIALTY CONCEPTS, INC. 1. Specialty Concepts, Inc. warrants all its products for a period of five (5) years from the date of shipment from its factory. This warranty is valid against defects in materials and workmanship for the five (5) year warranty period. It is not valid against defects resulting from, but not limited to: A. Misuse and/or abuse, neglect or accident. B. Exceeding the unit's design limits. C.