Campbell CH150 User manual

INSTRUCTION MANUAL
PS150/CH150
12 V Charging Regulators
Revision: 10/17
Copyright © 2000-2017
Campbell Scientific, Inc.

Limited Warranty
“Products manufactured by CSI are warranted by CSI to be free from defects in
materials and workmanship under normal use and service for twelve months
from the date of shipment unless otherwise specified in the corresponding
product manual. (Product manuals are available for review online at
www.campbellsci.com.) Products not manufactured by CSI, but that are resold
by CSI, are warranted only to the limits extended by the original manufacturer.
Batteries, fine-wire thermocouples, desiccant, and other consumables have no
warranty. CSI’s obligation under this warranty is limited to repairing or
replacing (at CSI’s option) defective Products, which shall be the sole and
exclusive remedy under this warranty. The Customer assumes all costs of
removing, reinstalling, and shipping defective Products to CSI. CSI will return
such Products by surface carrier prepaid within the continental United States of
America. To all other locations, CSI will return such Products best way CIP
(port of entry) per Incoterms ® 2010. This warranty shall not apply to any
Products which have been subjected to modification, misuse, neglect, improper
service, accidents of nature, or shipping damage. This warranty is in lieu of all
other warranties, expressed or implied. The warranty for installation services
performed by CSI such as programming to customer specifications, electrical
connections to Products manufactured by CSI, and Product specific training, is
part of CSI's product warranty. CSI EXPRESSLY DISCLAIMS AND
EXCLUDES ANY IMPLIED WARRANTIES OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE. CSI hereby disclaims,
to the fullest extent allowed by applicable law, any and all warranties and
conditions with respect to the Products, whether express, implied or
statutory, other than those expressly provided herein.”

Assistance
Products may not be returned without prior authorization. The following
contact information is for US and international customers residing in countries
served by Campbell Scientific, Inc. directly. Affiliate companies handle repairs
for customers within their territories. Please visit www.campbellsci.com to
determine which Campbell Scientific company serves your country.
To obtain a Returned Materials Authorization (RMA), contact CAMPBELL
SCIENTIFIC, INC., phone [phone]. Please write the issued RMA
number clearly on the outside of the shipping container. Campbell Scientific’s
shipping address is:
CAMPBELL SCIENTIFIC, INC.
RMA#_____
815 West 1800 North
Logan, Utah 84321-1784
For all returns, the customer must fill out a “Statement of Product Cleanliness
and Decontamination” form and comply with the requirements specified in it.
The form is available from our website at www.campbellsci.com/repair. A
completed form must be either emailed to [e-mail] or faxed to
[phone]. Campbell Scientific is unable to process any returns until we
receive this form. If the form is not received within three days of product
receipt or is incomplete, the product will be returned to the customer at the
customer’s expense. Campbell Scientific reserves the right to refuse service on
products that were exposed to contaminants that may cause health or safety
concerns for our employees.

Safety
DANGER — MANY HAZARDS ARE ASSOCIATED WITH INSTALLING, USING, MAINTAINING, AND WORKING ON OR AROUND
TRIPODS, TOWERS, AND ANY ATTACHMENTS TO TRIPODS AND TOWERS SUCH AS SENSORS, CROSSARMS, ENCLOSURES,
ANTENNAS, ETC. FAILURE TO PROPERLY AND COMPLETELY ASSEMBLE, INSTALL, OPERATE, USE, AND MAINTAIN TRIPODS,
TOWERS, AND ATTACHMENTS, AND FAILURE TO HEED WARNINGS, INCREASES THE RISK OF DEATH, ACCIDENT, SERIOUS
INJURY, PROPERTY DAMAGE, AND PRODUCT FAILURE. TAKE ALL REASONABLE PRECAUTIONS TO AVOID THESE HAZARDS.
CHECK WITH YOUR ORGANIZATION'S SAFETY COORDINATOR (OR POLICY) FOR PROCEDURES AND REQUIRED PROTECTIVE
EQUIPMENT PRIOR TO PERFORMING ANY WORK.
Use tripods, towers, and attachments to tripods and towers only for purposes for which they are designed. Do not exceed design limits.
Be familiar and comply with all instructions provided in product manuals. Manuals are available at www.campbellsci.com or by
telephoning [phone] (USA). You are responsible for conformance with governing codes and regulations, including safety
regulations, and the integrity and location of structures or land to which towers, tripods, and any attachments are attached. Installation
sites should be evaluated and approved by a qualified engineer. If questions or concerns arise regarding installation, use, or
maintenance of tripods, towers, attachments, or electrical connections, consult with a licensed and qualified engineer or electrician.
General
•Prior to performing site or installation work, obtain required approvals and permits. Comply
with all governing structure-height regulations, such as those of the FAA in the USA.
•Use only qualified personnel for installation, use, and maintenance of tripods and towers, and
any attachments to tripods and towers. The use of licensed and qualified contractors is highly
recommended.
•Read all applicable instructions carefully and understand procedures thoroughly before
beginning work.
•Wear a hardhat and eye protection, and take other appropriate safety precautions while
working on or around tripods and towers.
•Do not climb tripods or towers at any time, and prohibit climbing by other persons. Take
reasonable precautions to secure tripod and tower sites from trespassers.
•Use only manufacturer recommended parts, materials, and tools.
Utility and Electrical
•You can be killed or sustain serious bodily injury if the tripod, tower, or attachments you are
installing, constructing, using, or maintaining, or a tool, stake, or anchor, come in contact with
overhead or underground utility lines.
•Maintain a distance of at least one-and-one-half times structure height, 20 feet, or the distance
required by applicable law, whichever is greater, between overhead utility lines and the
structure (tripod, tower, attachments, or tools).
•Prior to performing site or installation work, inform all utility companies and have all
underground utilities marked.
•Comply with all electrical codes. Electrical equipment and related grounding devices should be
installed by a licensed and qualified electrician.
Elevated Work and Weather
•Exercise extreme caution when performing elevated work.
•Use appropriate equipment and safety practices.
•During installation and maintenance, keep tower and tripod sites clear of un-trained or non-
essential personnel. Take precautions to prevent elevated tools and objects from dropping.
•Do not perform any work in inclement weather, including wind, rain, snow, lightning, etc.
Maintenance
•Periodically (at least yearly) check for wear and damage, including corrosion, stress cracks,
frayed cables, loose cable clamps, cable tightness, etc. and take necessary corrective actions.
•Periodically (at least yearly) check electrical ground connections.
WHILE EVERY ATTEMPT IS MADE TO EMBODY THE HIGHEST DEGREE OF SAFETY IN ALL CAMPBELL SCIENTIFIC PRODUCTS,
THE CUSTOMER ASSUMES ALL RISK FROM ANY INJURY RESULTING FROM IMPROPER INSTALLATION, USE, OR
MAINTENANCE OF TRIPODS, TOWERS, OR ATTACHMENTS TO TRIPODS AND TOWERS SUCH AS SENSORS, CROSSARMS,
ENCLOSURES, ANTENNAS, ETC.

i
Table of Contents
PDF viewers: These page numbers refer to the printed version of this document. Use the
PDF reader bookmarks tab for links to specific sections.
1. Introduction ................................................................1
2. Precautions and Tips.................................................2
3. QuickStart...................................................................3
3.1 Connecting Power ................................................................................5
3.1.1 Solar Panel ....................................................................................5
3.1.2 AC/DC Power ...............................................................................6
3.2 Plug In the Battery ...............................................................................6
3.3 Hook Up Power to Datalogger.............................................................8
3.4 Turn On the Charging Source ..............................................................8
3.5 Turn On Power to the Datalogger ........................................................8
3.6 LED Indicator ......................................................................................9
4. Specifications.............................................................9
4.1 Specifications.......................................................................................9
4.2 Battery Packs .....................................................................................10
4.3 Charging Sources ...............................................................................10
5. Operational Overview ..............................................12
6. Charging Details.......................................................13
6.1 Charging Algorithm ...........................................................................13
6.2 Maximum Power Point Tracking .......................................................14
7. A100 Null Modem Adapter.......................................14
8. A105 Additional 12 V Terminals Adapter................15
9. References................................................................16
Figures
3-1. The PS150 connected to a CR1000 and AC power..............................3
3-2. The PS150 connected to a CR1000 and solar panel.............................4
3-3. CH150 connected to BP24 battery pack and CR1000 .........................4
3-4. Solar panel connections on PS150 .......................................................5
3-5. AC power connections on PS150.........................................................6
3-6. Lift latch up on PS150 .........................................................................7
3-7. Slide PS150 lid off ...............................................................................7
3-8. Wiring harness plugged into battery connector....................................8
5-1. CH/PS150 schematic..........................................................................12
6-1. 70 W solar panel I – V and power characteristics..............................14

Table of Contents
ii
7-1. Null modem connections................................................................... 15
7-2. PS150 with A100 module using a COM220 and RF450................... 15
8-1. A105 adapter ..................................................................................... 16

1
PS150/CH150 12 V Charging Regulators
1. Introduction
The PS150 is a 12 Vdc power supply that includes a rechargeable 7 Ah valve-
regulated lead-acid (VRLA) battery and charging regulator. The CH150 is a
charging regulator for an external rechargeable 12 V VRLA battery such as the
BP12 or BP24 offered by Campbell Scientific. Charging power for these
charging regulators is typically supplied by an unregulated solar panel, AC/AC
transformer, or AC/DC converter.
The PS150/CH150 are smart chargers that provide charging with temperature
compensation for optimal charging and battery life. A maximum power point
tracking algorithm is incorporated for solar inputs to maximize available solar
charging resources.
The PS150/CH150 are compatible with the A100 null-modem adapter and the
A105 adapter for additional 12 V output terminals. The A100 Null Modem
Adapter connects and powers two Campbell Scientific peripherals via two CS
I/O 9-pin connectors configured as a null modem. This is useful in linking
different communications technologies; e.g., telephone to radio, at sites that do
not have a datalogger. The A105 adapter may be used to provide additional 12
V and ground terminals where the power supply is used to power several
devices.
The PS150/CH150 charging regulators are termed series regulators, because
the regulators are placed in series between the charging source and the load. As
batteries become closer to fully charged, series regulators reduce the current
drawn from the charging source, to where the charging source may be
completely unloaded if full-charge is reached. While this unloading of the
charging source is acceptable for solar panels, AC/AC transformers and
AC/DC converters, it is undesirable for wind turbines because of the resulting
free spinning when unloaded. Consequently, series charging regulators,
including the PS150/CH150, should not be used to regulate the output of wind
turbines without the inclusion of a way to load the turbine when the batteries
require little or no charging current.
The PS150/CH150 chargers have several safety features intended to protect the
charging source, battery, charger, and load devices. Both the SOLAR – G and
CHARGE – CHARGE input terminals incorporate hardware current limits
and polarity reversal protection. There is a 5 A fuse in series with the
CHARGE – CHARGE inputs in the event of a catastrophic AC/AC or
AC/DC charging source failure. There is a 4.7 A solid-state breaker in series
with the 12 V output terminals of the charger in the event of an output load
fault. The PS150/CH150 incorporate battery reversal protection, which is
catastrophic for most chargers. ESD and surge protection are incorporated on
all inputs and outputs of the PS150/CH150.

PS150/CH150 12 V Charging Regulators
2
2. Precautions and Tips
For indoor use only.
Risk of electric shock. Dry location use only.
Risk of fire or electric shock. Do not interconnect output
terminals.
Permanent damage to rechargeable cells may result if
discharged below 10.5 V.
Under normal charging conditions with sealed VRLA batteries, hydrogen and
oxygen gasses are produced in relatively small quantities, most of which later
recombines back into water. Aggressive overcharging produces excess
hydrogen and oxygen gasses, resulting in gas venting by means of a pressure
activated valve. Hydrogen gas emitted from VRLA batteries must not be
allowed to accumulate, as it could form an explosive mixture. Fortunately,
hydrogen gas is difficult to contain in anything but a metal or glass enclosure.
Never put VRLA batteries in an enclosure that does not
allow emitted hydrogen gas to be dispersed.
VRLA batteries are capable of providing high surge currents. The 12 V output
terminals of the PS150/CH150 are fused with a 4 A self-resettable thermal
fuse, but there is no fusing for inadvertent bridging of the battery terminals.
Accidental shorting of battery terminals by metallic objects, such as
watchbands, can cause severe burns due to rapid heating and is also a fire
hazard.
VRLA battery manufacturers state that “Heat Kills Batteries”. While the
PS150/CH150 can operate from –40 to 60 °C, optimum battery life is achieved
with battery operating temperatures ranging from 5 to 35 °Ci, per
manufacturer’s recommendations1. The PS150/CH150 offer temperature
compensation of the battery charging voltage based on a temperature
measurement inside the PS150/CH150 cases. The CH150 internal temperature
measurement likely will not accurately represent battery temperature for charge
voltage compensation unless the battery is in close proximity to the CH150.
With rechargeable batteries, a charge →discharge →re-charge event is termed
a cycle. In general, the most important factor for the service life of a battery is
depth of discharge1. For example, decreasing the depth of each discharge from
iGenesis Application Manual – Genesis NP and NPX Series US-NP-AM-002,
June 2006.
CAUTION
WARNING
WARNING
WARNING
WARNING

PS150/CH150 12 V Charging Regulators
3
100% to 50% approximately doubles the number of useful cycles available
from the battery1.
Leaving a lead-acid battery in a discharged state for
prolonged periods of time results in the undesirable growth
of large sulfate crystals (sulfation) that are detrimental to
battery performance.
VRLA batteries self-discharge at approximately 3% of rated capacity per
month at room temperature1. A 3% of rated capacity per month self-discharge
results in 100% discharge in approximately 33 months (≈3 years) for a battery
stored at room temperature. Self-discharge increasing with increasing storage
temperature.
Periodic recharging of stored batteries every few months is
recommended to prevent irreversible sulfation due to prolonged
time in a discharged state.
3. QuickStart
The PS150/CH150 modules are designed to handle extreme conditions. The
modules have been designed with mounting holes on one inch centers for
mounting to a standard Campbell Scientific enclosure back plate — see the
enclosure manual for mounting suggestions. See FIGURE 3-1 through
FIGURE 3-3 for typical enclosure installations using a PS150/CH150.
FIGURE 3-1. The PS150 connected to a CR1000 and AC power
CAUTION
NOTE

PS150/CH150 12 V Charging Regulators
4
FIGURE 3-2. The PS150 connected to a CR1000 and solar panel
FIGURE 3-3. CH150 connected to BP24 battery pack and CR1000

PS150/CH150 12 V Charging Regulators
5
3.1 Connecting Power
Although the power supply and battery are low voltage,
they do have the ability to supply a high current and
could potentially heat up a metal ring, watch band, or
bracelet enough to burn skin or melt metal when
shorted. Remove rings, watches, or bracelets before
hooking up power and connecting a battery.
Unlike earlier Campbell Scientific power supplies, the CH/PS150 can have
both solar and AC power hooked up simultaneously.
Flip the power supply switch to Off before hooking up power to the power
supply.
The switch on the CH/PS150 only controls power going to the
12V and Gterminal blocks. The battery is continuously charged
regardless of the switch setting as long as a charging voltage is
present.
3.1.1 Solar Panel
To prevent sparking while wiring up the solar panel,
either lay the solar panel face down on its packing box
or cover it with something fairly opaque to block the
sunlight while wiring up the panel.
Connect the black (negative) lead from the solar panel to the terminal block
marked Gthat is directly adjacent to the SOLAR terminal block. Connect the
red (positive) lead from an unregulated solar panel to the terminal block
marked SOLAR. See FIGURE 3-4.
FIGURE 3-4. Solar panel connections on PS150
WARNING
NOTE
WARNING

PS150/CH150 12 V Charging Regulators
6
3.1.2 AC/DC Power
Double check the input voltages coming in to the charger/regulator with a volt
meter.
AC Input Voltage: 14 to 24 Vac RMS
DC Input Voltage: 15 to 40 Vdc
Exceeding the voltages listed above will damage the
power supply.
Disconnect the primary side of the AC/DC power before connecting wires to
the PS150.
Connect the secondary power supply leads to the two terminal blocks marked
CHG. There is no polarity on the CHG terminal blocks, so it does not matter
which wire goes to which CHG terminal block, but make sure there is only
ONE wire per block. See FIGURE 3-5.
FIGURE 3-5. AC power connections on PS150
3.2 Plug In the Battery
The battery used with the PS150 is shipped inside of the PS150 case if the
power supply is NOT installed inside an enclosure. If the PS150 is mounted
inside an enclosure, then the battery will be located separately packed in one of
the packing boxes. This is done to minimize any damage that could occur if the
power supply should get loose from its mounts inside the enclosure during
shipment. The battery will NOT be plugged into the PS150. This is done to
minimize discharging the battery.
To remove the lid from the PS150, pull up on the PS150 lid latch and slide the
lid off as shown in FIGURE 3-6 and FIGURE 3-7.
WARNING

PS150/CH150 12 V Charging Regulators
7
Do not remove the tape holding the battery wiring
harness to the top of the battery! The tape is used to
keep the battery wiring harness out of the way of the
rubber bumpers on the inside of the lid.
FIGURE 3-6. Lift latch up on PS150
FIGURE 3-7. Slide PS150 lid off
WARNING
Latch
Lift latch up.
Slide lid off.

PS150/CH150 12 V Charging Regulators
8
Plug the battery into the connector marked BATT. This connector is polarized
and will only allow the mating connector to be plugged in one way. Push the
connector all the way in until it locks in place.
FIGURE 3-8. Wiring harness plugged into battery connector
3.3 Hook Up Power to Datalogger
Both the PS150 and the CH150 come with a 1-foot black wire attached to one
of the Gterminal blocks and a 1-foot red wire attached to one of the 12V
terminal blocks. Attach the red wire from the power supply to the datalogger
Power terminal block marked 12V (Campbell Scientific part number 3768).
Attach the black wire from the power supply to the datalogger Power terminal
block marked G.
3.4 Turn On the Charging Source
Turn on the power going to the charging source or uncover the solar panel. The
green Charge LED will flash approximately once a second if all incoming
connections are correct and there is an adequate charging voltage present.
3.5 Turn On Power to the Datalogger
Flip the switch on the PS150/CH150 supply to On. Verify voltage to the
datalogger with a volt meter, or use a key pad display, or connect to the
datalogger with a laptop or PDA to make sure the datalogger is running
correctly.

PS150/CH150 12 V Charging Regulators
9
3.6 LED Indicator
The green Charge LED will flash approximately once a second if all incoming
connections are correct and there is an adequate charging voltage present.
4. Specifications
4.1 Specifications
(CHARGE - CHARGE terminals)
AC or DC Source:
AC – (18 to 24) VRMS internally
limited to 1.2 ARMS
DC – (16 to 40) Vdc internally limited to
0.85 Adc
(SOLAR -
⏚
terminals)
Solar Panel or Other DC Source1:
15 to 40 Vdc
Maximum Charging Current:
4.0 Adc typical; 3.2 to 4.9 Adc
depending upon individual charger
Battery Charging FLOAT Charging: Vbatt(T) =
13.65 – (24 mV)•(T – 25) +
(0.24 mV)•(T – 25)2, where T is
temperature in degrees Celsius
±1% Accuracy on charging voltage over
–40 to 60 °C range
Operational Temperature Range2: –40 to 60 °C
Power Out (+12 terminals)
Voltage: Unregulated 12 V from Battery
4.65 A solid-state circuit breaker
Quiescent Current
No Charge Source Present: 160 µA at 13.7 Vdc
No Battery Connected: 930 µA at 30 volt input voltage (ac or
dc)
Rated UL Class 2 Power Supply
Physical Specifications
PS150: 10.6 cm (4.2 in) tall, 19.3 cm (7.5 in)
long, 7.6 cm (3 in) wide
CH150: 10.0 cm (3.9 in) tall, 7.5 cm (3 in) long,
3.7 cm (1.5 in) wide
Compliance: View the EU Declaration of Conformity
at www.campbellsci.com/ps150
1Battery voltages below 8.7 V may result in < 3.0 A current limit because of foldback
current limit.
2VRLA battery manufacturers state that “heat kills batteries” and recommend operating
batteries ≤50 °C.

PS150/CH150 12 V Charging Regulators
10
4.2 Battery Packs
Battery
Pack
Model
Amp-Hour
Capacity (Ah)
*Operating
Temperature
Range (ºC)
Battery Family
PS150 7 Charge: –15 to 50
Discharge: –20 to 60 EnerSys/Genesis
BP12 12 Charge: –15 to 50
Discharge: –20 to 60 EnerSys/Genesis
BP24 24 Charge: –15 to 50
Discharge: –20 to 60 EnerSys/Genesis
BP84 84 –40 to +71 Concorde Sun Xtender
* Battery specifications shown are from the manufacturer. The PS150/CH150 contains
charging algorithms that optimize battery charging over the range of –40 to 50 °C.
Battery usage outside of manufacturer specifications could have unknown effects on the
life of the battery.
Battery life is shortened if the battery is allowed to
discharge below 11.5 V.
4.3 Charging Sources
Campbell Scientific Solar Panels
SP10 SP20 SP50
Peak Power 10 W 20 W 50 W
Voltage @ Peak Power 16.8 V 16.8 V 17.5 V
Current @ Peak Power 0.59 A 1.19 A 3.9 A
Notes:
1. Specifications assume a 1 kilowatt per square meter illumination and a
solar panel temperature of 25 °C (77 °F).
2. Individual panels may vary up to 10%.
3. The output panel voltage increases as the panel temperature decreases,
which is in the same direction as the recommended VRLA battery
charging voltage change with temperature.
4. Higher latitudes and less sun hours during winter months might require a
larger panel than what is required to keep the battery charged during the
summer.
WARNING

PS150/CH150 12 V Charging Regulators
11
AC/DC Transformer with Interchangeable Blades: Campbell Scientific
Model No. 29796-US
Input Voltage: 100 – 240 Vac
Input Frequency: 47 – 63 Hz
Output Voltage: 24 Vdc
Output Current (max): 1.67 A
Protection: Unit will auto-recover upon removal of fault.
UL Approval: UL60950-1 2nd Edition
Unit has interchangeable blades. Unit ships with US/Canada plug installed.
For international orders select option 29798 –IP for international blades.
International blade selection contains blades for Australia/New Zealand, UK,
Europe/South America, Korea, Argentina, China, & India/South Africa.
AC/DC DIN Rail Mount Power Adapter: Campbell Scientific Model No.
28370
Input Voltage: 85 – 240 Vac or 90 – 350 Vdc
Input Frequency: 45 – 65 Hz
Output Voltage: 24 Vdc
Output Current: 3.8A (–25 to 70 °C)
Protection: 3.15A internal slow-blow fuse
Approval: ETL Listed for US and Canada
Both of the recommended chargers have dc voltage output which
can be used on either the CHARGE/CHARGE or SOLAR/G
terminal blocks. Maximum input charging current on the
CHARGE/CHARGE terminal blocks is limited to 1.1 Adc.
Maximum input charging current on the SOLAR/G terminal
blocks is limited to 3.6 Adc.
CHARGE/CHARGE terminal blocks have no polarity. Power wires from the
charging source can be connected in any fashion. The PS150/CH150 will only
float charge a battery with power connected to the CHARGE/CHARGE
terminal blocks which is fine when using an AC/DC charging source.
SOLAR/G terminal blocks do have a polarity that must be followed when
wiring up either of the AC/DC devices. Positive wire goes to the terminal block
marked SOLAR. Negative wire goes to the terminal block marked G. Higher
power throughput makes this an attractive option. It will float charge a battery
but it will also try to quick charge as well depending on the needs of the
battery.
NOTE

PS150/CH150 12 V Charging Regulators
12
5. Operational Overview
A simplified schematic of the CH/PS150 charging regulator is illustrated in
FIGURE 5-1. A 12-V 7Amp-hr rechargeable battery is included with the
PS150, whereas the user provides the rechargeable battery, such as the BP12 or
BP24 offered by Campbell Scientific, Inc., for the CH150. See Section 4.2,
Battery Packs (p. 10), for rechargeable batteries offered for the CH150 by
Campbell Scientific.
FIGURE 5-1. CH/PS150 schematic
Charging power for the PS150/CH150 is typically supplied by an unregulated
solar panel, AC/AC transformer, or AC/DC converter. The CHARGE –
CHARGE terminals are connected to a diode bridge, accommodating either
AC or DC voltages from a charge source. Because of the diode bridge, polarity
does not matter when connecting sources to the CHARGE – CHARGE input
terminals. In order to protect AC/AC or AC/DC sources when charging
discharged batteries, the CHARGE – CHARGE input terminals offer an
approximately 1.1 amps DC (1.2 A RMS) current limit. The SOLAR – G input