Atkinson Electronics PVLC-40MD User manual

PV CHARGE & LIGHTING CONTROLLER W/ Motion Sensor 40 Amp PVLC-40MD
ATKINSON ELECTRONICS, INC. REV 09/07
Web Site: www.atkinsonelectronics.com Distributed by:
FEATURES
vPV charge & lighting controller - waterproof
vMicro-controller for digital accuracy and reliability
vFully automatic operation on 12/24V DC systems
vAutomatic dusk and dawn lighting control
vMotion Sensor activated lighting control.
vWill handle up to 40 Amps @ 28VDC from PV panels
and lighting loads up to 40 Amps
vBuilt-in temperature compensation for PV charging
vLED indication of solar charge & lighting control
vPulse action reduces battery sulfation
APPLICATIONS
vPhoto Voltaic charge and lighting controller for:
security lighting, roadside rest rooms, etc.
OPERATION
The PVLC-40MD Charge controller monitors both the battery
and PV panel voltage, if PV panels have sufficient voltage for
charge,and if the battery bank requires charging. When
charging the PVLC-40MD cycles the charge relay every 4
minutes to re-verify open circuit PV charge voltage to avoid
discharging the batteries through the PV panels when low
light conditions occur. The charge re-connection time is
varied by the micro-processor to optimally reduce the charge
rate for nearly or fully charged batteries. The PVLC-40MD
internal temperature compensation adjusts the charge
threshold voltages for optimum charge of the battery bank
based on temperatures between 08C to 458C. For a complete
chartPVLC-40MD Temperature Thresholds section next
page.
The PVLC-40MD Lighting controller monitors the motion
sensor, PV panel voltage and battery voltage and initiates
the “light-on” cycle when either the motion sensor has been
activated or a dusk voltage threshold has been reached for
dusk to dawn operation. The relay remains energized until
either the time selection is reached, the PV voltage indicates
dawn, or the battery voltage drops below 11.3V DC for 5
continuousminutes. If the lighting relay drops out on low
battery voltage or is below 12V at dusk, it will not re-energize
until the battery has been charged up to 12.4V DC.
The PVLC-40MD has ten lighting settings (See PVLC-40MD
switch - lighting adjustments for timing selections). There is
OFF, 4 night only settings, Dusk to Dawn setting, and 4
anytime settings. Selecting (5) “Dusk to Dawn” on the timing
switch causes the lights to turn on at dusk and remain on
until dawn (subject to the low battery voltage cutout). The
PVLC-40MD also can have an optional 5 or 10 minute max
lighting time within a 30 minute period. By clipping either the
White (5 min) or Gray (10min) jumpers this activates the
max lighting routine.
SPECIFICATIONS
SIZE/WEIGHT: 3.3"W x 5.5"L x 1.65"H
ENCLOSURE: Epoxy potted in PVC plastic
MOUNTING: Two 1/2" #8 screws (required)
POWER: 9.5 to 35 V DC from storage battery
LOAD CAPACITY: 40 Amps @ 28V DC (NO contact)
CONNECTIONS: 1/4" Bolt Connectors
Ring Connector Molex #BCL814PL
1/4" Spade Battery Negative (-)
FLOODED BATTERY On @ 12.7V DC, Off @ 14.2V DC
PV CHARGE: @ Room temperature 15-308C
GEL CELL BATTERY *Blue Jumper Clipped*
PV CHARGE: On @ 12.4V DC, Off @ 13.9V DC
TIMING RANGE 4 After Dusk Settings (1-4 minutes)
SWITCH: 1 All Night, 1 Off - no lighting
(10 Settings) 4 Anytime Settings (1-4 minutes)
TEMPERATURE
COMPENSATION: 0.040V/8C for 12V systems
CURRENT DRAW: Continuous - [ 5.3mA
During charge mode 60mA Nominal,
During lighting mode 60mA Nominal,
Both charge & light mode 120mA
LED INDICATION: Red Charging Mode
Yellow Lighting Cycle ‘on’
MINIMUMS: 9.5V DC battery for PV charge
11.3V DC battery for lighting relay
PV Charge Current - 80mA
Open PV - 16V (12V system)
TEMPERATURE: -30 to 758C
RELAY LIFE: 100 million mechanical operations
MOTION SENSOR: Honeywell - IS-215T N.C. contact
8.5ma current draw continuous
Double the 12V system values for 24V system values
ORDERING INFORMATION
PVLC-40MD -Photo-Voltaic charge & Lighting
Controller module W/ motion
detector input.

PV CHARGE & LIGHTING CONTROLLER W/ Motion Sensor 40 Amp PVLC-40MD
ATKINSON ELECTRONICS, INC. REV 09/07
Web Site: www.atkinsonelectronics.com Distributed by:
PVLC-40 TEMPERATURE THRESHOLDS PVLC-40 SWITCH - LIGHTING ADJUSTMENTS
Below 08C-On @ 13.3V, Off @ 15.0V Pos. “0" -Off
Between 0-58C-On @ 13.3V, Off @ 14.8V
Between 5-108C-On @ 13.1V, Off @ 14.6V
Between 10-158C-On @ 12.9V, Off @ 14.4V
Between 15-308C-On @ 12.7V, Off @ 14.2V
Between 30-358C-On @ 12.7V, Off @ 14.0V
Between 35-408C-On @ 12.6V, Off @ 13.8V
Between 40-458C-On @ 12.6V, Off @ 13.6V
Above 458C-On @ 12.6V, Off @ 13.4V
Pos. “1" -On for 1 min after sensor activation - night
Pos. “2" -On for 2 mins after sensor activation
Pos. “3" -On for 3 mins after sensor activation
Pos. “4" -On for 4 mins after sensor activation
Pos. “5" -On from dusk to dawn
Pos. “6" -On for 1 min after sensor activation - anytime
Pos. “7" -On for 2 mins after sensor activation
Pos. “8" -On for 3 mins after sensor activation
Pos. “9" -On for 4 mins after sensor activation
WIRING DIAGRAM - LIGHTING CONTROL APPLICATION
INSTALLATION AND STARTUP INSTRUCTIONS
1. Connect the PV panel and lighting load negative wires to the negative battery post. Connect the PVLC-40MD Red (+) wire
to the Battery positive post and the PVLC-40MD Yellow wire to the PV panel + wire. Connect the Motion sensor to the
PVLC-40MD using the 3 wire 18awg cable, red to (+), black to (-), White to (NC), Jumper between (-) and other (C).
2. Adjust the desired time range on the switch per PVLC-40MD switch lighting options.
3. Now connect the PVLC-40MD Black wire to the battery negative terminal to power up the PVLC-40MD. Verify that the initial
battery voltage is greater than 11.3V or 22.6V, and PV voltage is greater than 16V or 32V.
4. Twelve seconds after power up, the charge relay (red LED) will click the number of times per the switch position with “0"
being 10. If the switch did not get set to the desired position, disconnect the PVLC-40MD’s negative battery wire and reset
switchto desired lighting operation and timing range. Reconnect the PVLC-40MD's negative battery wire and verify the
desired timing range. If the open circuit PV voltage is above 16V (32V) and the battery voltage is below the “turn on”
threshold (12.7VDC), then the PV charge relay will energize, charging the battery. Every 4 minutes the PV relay will drop-
out momentarily to test for the presence of adequate PV charge sunlight.
5. To test the lighting function, wave your hand in front of the motion sensor. If lighting set for night only then disconnect the
PV Yellow wire, wave your hand in front of the motion sensor, the lighting relay (yellow LED) will turn on the lighting load.
6. Now disconnect the PVLC-40MD black wire and reconnect the yellow PV wire, and then reconnect the black wire.
7. Mount the PVLC-40MD securely with screws and coat the switch with silicone to insure that the entire module is waterproof.
Waterproof the electrical connections with silicone or grease.
Note: The PVLC-40MD is powered by either the battery or PV voltage, which ever is greater. The charge relay is only powered
from the PV voltage and the lighting relay is only power by the battery voltage. If there is insufficient PV voltage when
powering up the PVLC-40MD, the charge relay will only click once after a 12 second delay. If there is sufficient PV
voltage( >16V/32V), then after a 12 second delay the PV relay will click out the switch position with “0" being 10 clicks,
it then checks the Battery voltage, if its below the “turn on” threshold, the charge relay energizes after a delay of 5
seconds. If battery voltage is above the turn on threshold, then it will wait until it drops below the threshold.

PV CHARGE & LIGHTING CONTROLLER W/ Motion Sensor 40 Amp PVLC-40MD
ATKINSON ELECTRONICS, INC. REV 09/07
Web Site: www.atkinsonelectronics.com Distributed by:
PVLC-15MD WIRE IDENTIFICATION DIAGRAM
TROUBLESHOOTING TIPS
Problem -Module doesn’t click on charge relay and there is sunlight on the PV panels.
Solution -Verify that the battery voltage is less than 12.70V (or 25.4V on a 24V DC system) for temperatures between
15-358C (see Temperature Threshold setting previous page) and that the open PV voltage is greater than 16V
or (32V). If both conditions are met, wait for the 4 minute delay period to cycle.
-Try resetting the PVLC-40MD by disconnecting the Black wire for 10 seconds and then reconnecting it,
PVLC-40MD will go thru it’s startup routine and click out the switch settings, then to normal operation.
Problem -Module clicks every several minute .
Solution -This is the normal operating sequence.
Problem -Module charges for a few seconds then shuts off for 4 minutes.
Solution -The Batteries are fully charged and the charge current was at maximum output, verify battery voltage is greater
than 14.2VDC. It may also mean that the Batteries have a poor connection or a bad cell with high internal
resistance.
Problem -Module switches on for 1 or 2 minutes and then is off for a much longer period of time.
Solution -This is also normal if the battery is at or nearly fully charged and the PV charge current is at or near maximum.
Problem -The battery load has been left on and the storage battery has discharged below 8V DC. The PV system is not
charging when the load is turned off.
Solution -The PVLC-40MD needs at least 9.5V DC from the battery to operate properly. Place the panel in direct sunlight
and jumper the red and yellow wires for a few minutes, thus bypassing the charge controller allowing the
battery voltage to rise to at least 8V DC. Disconnecting the jumper will allow the PVLC-40 to charge the
battery up to normal levels.
Problem -The module is set for lighting control and at dusk fails to turn on lights.
Solution -The PVLC-40MD checks the battery voltage at dusk to see if batteries are greater than 12V (or 24V) DC,
sufficient to run lights. If not, it locks out lighting relay until the solar panels have charged battery above 12V
DC (24V DC).
Problem -The motion detector does not indicated movement after power up.
Solution -The motion detector has a 30 to 45 second delay before sensing movement.