Magnum Energy PT-100 User manual

PT-100
MPPT Charge Controller
Owner’s Manual

© 2017 Sensata Technologies Page i
Record the unit’s serial number in case you need to provide it in the future. It may save
time and be easier to record it now, instead of trying to obtain it after it is installed.
Model: Serial Number:
PT-100 TB or WTB-
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.
Disclaimer of Liability
This manual provides detailed installation and operation information for the PT-100 charge controller
and is intended for the system installer and operator. The use of this manual and the conditions
or methods of installation, operation, use and maintenance of the PT-100 controller are beyond
the control of Sensata Technologies. Therefore, this company does not assume responsibility and
expressly disclaims liability for loss, damage, or expense whether direct, indirect, consequential
or incidental that may arise out of or be any way connected with such installation, operation, use,
or maintenance.
Due to continuous improvements and product updates, the images shown in this manual may not
exactly match the unit purchased.
Restrictions on Use
The PT-100 may only be used in life support devices and systems with the express written approval
of Sensata Technologies. Failure of this charge controller can reasonably be expected to cause
failure of that life support device or system, or to affect the safety or effectiveness of that device
or system. If the PT-100 fails, it is reasonable to assume the health of the user or other persons
may be endangered.
Copyright Notice
Copyright © 2017 by Sensata Technologies. All rights reserved. Permission to copy, distribute, and/
or modify this document is prohibited without express written permission from Sensata Technologies.
Document Information
Description – PT-100 Owner’s Manual
Part Number and Revision – 64-0067 Rev B
Date Published – December 2017
This is a comprehensive manual and much of it is fairly technical. Terms may be used
throughout the manual that are unfamiliar to you. Refer to the glossary in Appendix C for
clarification. This manual is printed without color for cost savings. However, this entire manual
is available for download—with many of the figures available in color—online at our website at
www.SensataPower.com.
Contact Information
For Magnum Energy Products:
Sensata Technologies
Phone: [phone]
Fax: [phone]
Web: www.SensataPower.com

Safety Information
Page ii
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. Do not perform any installation or servicing other than
that specified in this owner’s manual unless you are qualified to do so. Incorrect installation or
servicing may result in a risk of electric shock, fire, or other safety hazard.
Safety Symbols
The following safety symbols have been placed throughout this manual to indicate potentially
dangerous or important safety instructions.
WARNING: This symbol indicates that failure to take a specified action could result in
physical harm to the user.
CAUTION: This symbol indicates that failure to take a specified action could result in
damage to the equipment.
Info: This symbol indicates information that emphasizes or supplements important
points of the main text.
GROUND: This symbol indicates the connection point intended for the equipment-
grounding conductors, and is located in the wiring compartment.
Safety Precautions
• All electrical work must be performed in accordance with local and national electrical codes.
• This product is designed for indoor/compartment installation. It must not be exposed to rain,
snow, moisture, or liquids of any type.
• There are no user-serviceable parts contained in this controller; do not disassemble or attempt
to repair. Refer servicing to qualified service personnel.
• Since a charge controller utilizes PV power and batteries, power may be present at more than
one point. To reduce risk of electric shock, ensure both battery and PV power are disconnected
prior to performing maintenance. Turning off the charge controller will not reduce this risk, the
charge controller must be totally disconnected from all sources of power.
• When exposed to sunlight, PV modules can generate current and voltage on its output wires/
terminals. Before making any connections, de-energize the PV modules, either by removing them
entirely from light or completely covering their front surface with an opaque (dark) material.
• Listed or labeled equipment shall be installed and used in accordance with any instructions
included in the listing or labeling.
• Always verify proper wiring prior to starting the charge controller.
• Use only copper wires with a minimum temperature rating of 167°F (75°C).
• Torque all wire connections to the required torque values.
• The charge controller must be properly mounted and installed in a proper location. See Section
2.3 for information on mounting and location requirements.
• Overcurrent protection (i.e., fuses/circuit breakers) is not provided as an integral part of this
charge controller. Overcurrent protection for the PV and battery wiring must be provided as
part of the system installation.
• This device is provided with integral PV Ground Fault Detector/Interrupter (GFDI). Normally
grounded conductors may be ungrounded and energized when a ground-fault is indicated.
• The heatsink of the controller can exceed 167°F (75°C); to reduce the risk of burns, do not touch.
• Internal capacitors may have stored energy. Once all sources of power has been disconnected,
wait at least 5 minutes before removing the access cover.

© 2017 Sensata Technologies Page iii
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. Keep any fluid/corrosion on the battery from
coming in contact with eyes and skin. Have plenty of fresh water and soap nearby and
thoroughly wash in case battery acid contacts skin, clothing, or eyes. In the event of
exposure to the eyes, flood them for at least 15 minutes with running water and seek
immediate medical attention. Baking soda neutralizes lead acid battery electrolyte and
vinegar neutralizes spilled NiCad and NiFe battery electrolyte; depending on your battery
type, keep a supply on hand near the batteries.
• A battery can present a risk of electrical shock and high short-circuit. Remove watches,
rings, or other metal objects when installing or performing maintenance on the batteries
and charge controller. A battery can produce a short-circuit current high enough to weld
metal jewelry, causing severe burns.
• Use insulated tools and be very careful when working around batteries, they can produce
extremely high currents if short-circuited (e.g., dropping or laying a metal tool across the
battery terminal), which could cause a fire or explosion.
• Wear rubber gloves and boots when working around batteries.
• Disconnect charging source prior to connecting or disconnecting battery terminals.
• Determine if battery is inadvertently grounded. If inadvertently grounded, remove source
from ground. Contact with any part of a grounded battery can result in electrical shock. The
likelihood of such shock can be reduced if such grounds are removed during installation
and maintenance.
• Read and follow the battery manufacturer’s safety precautions before installing the charge
controller and batteries. Always verify proper polarity and voltage before connecting
the batteries to the charge controller. Once the batteries are connected to the charge
controller, ensure all charging or maintenance requirements (i.e., charge voltage and
charge rate) provided by the battery manufacturer are followed to extend the life of the
batteries and to prevent damage to the batteries while charging.
• Never work alone. Always have someone within the range of your voice or close enough
to come to your aid when working around batteries.
• Use proper lifting techniques when working with batteries.
• Never use old or untested batteries. Ensure the battery age, type and date code on all
batteries are identical.
• Batteries can produce explosive gasses, so install batteries in a well-ventilated area.
For batteries installed in a compartment or enclosure, always vent batteries from the
highest point to the outside. Design the battery enclosure to prevent an accumulation and
concentration of hydrogen gas in pockets at the top of the compartment.
• Never smoke or allow a spark near batteries.
• To prevent a spark at the battery and reduce the chance of explosion, always connect the
cables to the batteries first. Then connect the cables to the charge controller.
• Never charge a frozen battery.
• The battery bank should be installed in a clean, dry, ventilated environment where they
are protected from high and low temperatures. The location must be fully accessible and
protected from exposure to heat producing devices, and away from any fuel tanks.

Safety Information
Page iv
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. Ne pas effectuer une installation ou
d’entretien autres que ceux spécifiés dans ce manuel, sauf si vous êtes qualifié pour le faire. Une
mauvaise installation ou d’entretien peut entraîner un risque de choc électrique, un incendie ou autre
danger pour la sécurité.
Symboles de sécurité
Les symboles de sécurité suivants ont été placéstout au long de ce manuel pour indiquer des
conditions dangereuses et les consignes de sécurité importantes.
AVERTISSEMENT: Ce symbole indique que le défaut de prendre une action spécifiée
pourraitcauser des dommages physiques à l’utilisateur.
ATTENTION: Ce symbole indique que le défaut de prendre une action spécifiée peut
entraîner des dommages à l’équipement.
Info: Ce symbole indique une information qui met l’accent ou des suppléments points
importants du texte principal.
Gound: Ce symbole indique la terninal pour le raccordement de conducteurs à la terre,
et se trouve dans le compartiment de câblage.
Consignes de sécurité
• Tous les travaux électriques doivent être effectués en conformité avec les codes locaux et
nationaux électriques.
• Ce produit est conçu pour l’installation / du compartiment intérieur. Il ne doit pas être exposé
à la pluie, la neige, l’humidité ou des liquides de tout type.
• Il n’y a pas de pièces réparables par l’utilisateur contenues dans ce contrôleur, ne pas démonter
ou tenter de réparer. Confiez l’entretien à du personnel qualifié.
• Depuis un contrôleur de charge utilise des batteries et la puissance PV, l’énergie peut être
présente à plus d’un point. Pour réduire les risques de choc électrique, assurent à la fois la
batterie et la puissance PV sont débranchés avant d’effectuer l’entretien. La désactivation
du régulateur de charge ne sera pas réduire ce risque, le régulateur de charge doit être
totalement déconnecté de toutes les sources d’alimentation.
• Coté ou étiquetés équipement doit être installé et utilisé conformément aux instructions
figurant dans la liste ou l’étiquetage.
• Toujours vérifier le câblage avant de commencer l’onduleur.
• Utilisez uniquement des câbles en cuivre avec une cote de température minimale de 167 ° F (75°C).
• Serrer toutes les connexions pour les valeurs de couple requis.
• Le régulateur de charge doit être correctement monté et installé dans un endroit approprié.
Voir la section 2.3 pour obtenir des informations sur le montage et les exigences de localisation.
• Protection contre les surintensités (c.-à-fusible / disjoncteur) n’est pas prévue comme faisant
partie du régulateur de charge. Protection contre les surintensités pour les PV et câblage de
la batterie doit être fournie dans le cadre de l’installation du système.
• Ce contrôleur est fourni avec PV Rez détecteur / interrupteur de défaut intégrale (GFDI).
Normalement conducteurs mis à la terre ne peuvent pas être connectées électriquement à la
masse et peuvent être alimentés dans le cas d’un défaut à la terre est indiquée.
• Certaines surfaces de la controller peuvent dépasser 167°F (75°C), de réduire le risque de
brûlures, ne pas toucher.
• Condensateurs internes peuvent avoir stocké l’énergie. Ne pas retirer couvercle jusqu’à ce
que 5 minutes après déconnectant toutes les sources d’énergie .

© 2017 Sensata Technologies Page v
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. Porter des lunettes de protection tels que des lunettes
de sécurité, et éviter de toucher vos yeux et le visage lorsque vous travaillez avec des
batteries. Ne laissez aucun fluide / corrosion sur la batterie pour toucher les yeux et la
peau. Avoir beaucoup d’eau fraîche et du savon à proximité et se laver à fond si l’acide de
la batterie arrive à obtenir sur la peau, les vêtements ou les yeux. En cas d’exposition aux
yeux, les rincer pendant au moins 15 minutes à l’eau courante et consulter immédiatement
un médecin. Le bicarbonate de soude neutralise la batterie plomb-acide électrolyte et le
vinaigre neutralise déversés NiCad et NiFe électrolyte de batterie; en fonction de votre
type de batterie, gardez sous la main près des batteries.
• Une batterie peut présenter un risque de choc électrique et de court-circuit élevé. Retirer
montres, bagues ou autres objets métalliques lors de l’installation ou de maintenance
sur les batteries et le régulateur de charge. Une batterie peut produire un court-circuit
suffisamment élevé pour souder les bijoux en métal, ce qui provoque de graves brûlures.
• Utiliser des outils isolés et être très prudent lorsque vous travaillez à proximité des
batteries, ils peuvent produire des courants extrêmement élevés si un court-circuit (par
exemple, une chute ou placer un outil métallique entre la borne de la batterie), cela
pourrait provoquer un incendie ou une explosion.
• Porter des gants et bottes en caoutchouc lorsqu’ils travaillent près des batteries.
• Déconnectez la source de charge avant de connecter ou déconnecter la batterie.
• Déterminer si la batterie est mise à la terre par inadvertance. Si la terre par inadvertance,
retirer la source à partir du sol. Pour entrer en contact avec une partie quelconque d’une
batterie mise à la terre peut provoquer un choc électrique. La probabilité d’un tel choc
peut être réduite si ces motifs sont supprimés lors de l’installation et la maintenance.
• Lisez et suivez les consignes de sécurité du fabricant de la batterie avant d’installer le
contrôleur de charge et des batteries. Toujours vérifier la polarité et la tension avant de
connecter la batterie au contrôleur de charge. Une fois que les batteries sont connectées
au dispositif de commande de charge, assurer que toutes les exigences en matière de
charge ou d’entretien (par exemple, la tension de charge et le taux de charge) fourni par
le fabricant de la batterie sont suivies pour prolonger la durée de vie de la batterie et pour
éviter d’endommager la batterie en cours de charge.
• Ne jamais travailler seul. Toujours avoir quelqu’un dans la plage de votre voix ou
suffisamment près pour venir à votre aide lorsqu’ils travaillent près des batteries.
• Utiliser des techniques de levage appropriées lorsqu’ils travaillent avec des batteries.
• Ne jamais utiliser de piles usagées ou non testés. Veiller à l’âge de la batterie, le type et
le code de date à toutes les batteries sont identiques.
• Les batteries peuvent produire des gaz explosifs, donc installer les piles dans un endroit
bien ventilé. Pour les batteries installées dans un compartiment ou une enceinte, toujours
vent du point le plus élevé à l’extérieur. Concevoir le boîtier de batterie pour empêcher
l’accumulation et la concentration de l’hydrogène gazeux dans des poches dans la partie
supérieure du compartiment.
• Ne jamais fumer ou permettre une étincelle près des batteries.
• TPour éviter une étincelle à la batterie et réduire les risques d’explosion, toujours connecter
les câbles aux batteries d’abord. Ensuite, connectez les câbles au contrôleur de charge.
• Ne jamais charger une batterie gelée.
• La banque de la batterie doit être installé dans un environnement propre, sec et aéré
où ils sont protégés contre les hautes et basses températures. L’emplacement doit être
entièrement accessible et protégé contre l’exposition à la chaleur des dispositifs de
production, et loin de toute réservoirs de carburant.

Page vi © 2017 Sensata Technologies
Table of Contents
Disclaimer of Liability............................................................................................ i
Restrictions on Use............................................................................................... i
Copyright Notice .................................................................................................. i
Document Information .......................................................................................... i
Contact Information.............................................................................................. i
IMPORTANT SAFETY INSTRUCTIONS .......................................................................ii
CONSIGNES DE SÉCURITÉ IMPORTANTES...............................................................iv
1.0 Introduction..................................................................................1
1.1 Key Features and Benefits........................................................................... 1
1.2 Regulatory Compliance ............................................................................... 1
1.3 Physical Features....................................................................................... 2
2.0 Installation ...................................................................................5
2.1 Pre-Installation.......................................................................................... 5
2.2 PV System Components.............................................................................. 6
2.3 Locating and Mounting the PT Controller ...................................................... 7
2.4 Electrical System Wiring Diagrams ..............................................................16
2.5 PV Voltage Requirements...........................................................................17
2.6 Conductor Sizing for the PV System ............................................................23
2.7 Wiring the PT-100.....................................................................................32
2.8 Wiring the Battery Temperature Sensor .......................................................39
2.9 Wiring the Auxiliary Relay ..........................................................................40
2.10 Network Wiring ........................................................................................41
2.11 Stacking Installation - Wiring Multiple PT Controllers Together ........................45
2.12 Final Inspection/Tests................................................................................50
3.0 Setup ..........................................................................................52
3.1 Adjust DIP Switch Settings.........................................................................52
4.0 Operation....................................................................................56
4.1 PT Front Panel Features .............................................................................56
4.2 Front Panel Operation................................................................................57
4.3 MPPT Operation........................................................................................62
4.4 Charger Control Operation .........................................................................63
4.5 Ground Fault Detection and Interruption (GFDI) Operation .............................65
4.6 Arc-Fault Protection Operation ....................................................................66
4.7 Battery Temperature Sensor Operation ........................................................67
4.8 Charge Controller Fan Operation .................................................................68
4.9 PowerSave Operation ................................................................................68
4.10 Auxiliary Relay Operation...........................................................................69
4.11 Internal Beeper Operation..........................................................................69
4.12 Operating Configuration - Standalone vs Networked ......................................70
4.13 Stacking Operation ...................................................................................71
5.0 Maintenance and Troubleshooting...............................................74
5.1 Periodic Maintenance.................................................................................74
5.2 Basic Troubleshooting................................................................................75
5.3 Troubleshooting Based on Fault Codes .........................................................75
5.4 Stacking Fault Codes.................................................................................79
5.5 Removing/Replacing the GFDI Fuse.............................................................81
5.6 Removing and Replacing the Electronics Section ...........................................82
5.7 Resetting the PT-100 Charge Controller .......................................................83
5.8 Updating the PT-100’s Firmware .................................................................84

© 2017 Sensata Technologies Page vii
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 Limited Warranty ......................................................................................92
E-2 How to Receive Repair Service....................................................................92
List of Tables
Table 2-1, PV Input Voltage Parameters..........................................................................17
Table 2-2, Allowable Conductor Ampacities......................................................................30
Table 2-3, Ambient Temperature Adjustments .................................................................30
Table 2-4, Rooftop Distance Adjustments ........................................................................31
Table 2-5, Multiple Conductors in Raceway/Cable Adjustments...........................................31
Table 2-6, Torque Values for the DC Terminal Block ..........................................................33
Table 2-7, Torque Values for the Ground Busbar...............................................................33
Table 2-8, Recommended DC Wire/Overcurrent Device for PT-100......................................34
Table 2-9, Equipment Grounding Conductor Sizing ...........................................................35
Table 2-10, Remote Compatibility Version .......................................................................42
Table 3-1, Battery Type to Charge Voltages .....................................................................53
Table 3-2, Summary of DIP Switch Position .....................................................................55
Table 4-1, Charge Status LED Indicators .........................................................................58
Table 4-2, Power Status Code Descriptions......................................................................59
Table 4-3, Controller Settings (Standalone vs Networked) .................................................70
Table 5-1, Basic Controller Troubleshooting (Remote not available).....................................75
Table 5-2, Fault Code Descriptions .................................................................................75
Table 5-3, Stack Fault Code Descriptions.........................................................................79

Page viii © 2017 Sensata Technologies
List of Figures
Figure 1-1, Front Features ............................................................................................. 2
Figure 1-2, Internal Features ......................................................................................... 3
Figure 1-3, Side Features .............................................................................................. 4
Figure 2-1, Simplified PV System.................................................................................... 6
Figure 2-2, Removing the Access Cover ........................................................................... 7
Figure 2-3, Removing Knockouts .................................................................................... 7
Figure 2-4, PT-100 Dimensions and Knockout Locations..................................................... 8
Figure 2-5, Mounting Orientations................................................................................... 9
Figure 2-6, Air Flow in and around PT.............................................................................10
Figure 2-7, Minimum Mounting Clearance Requirements ...................................................10
Figure 2-8, Mounting the PT-100 Controller on a Magnum Panel.........................................11
Figure 2-9, Holes Used to Mount Bracket on MMP Enclosure ..............................................12
Figure 2-10, Mounting Bracket Thru-hole Callouts ............................................................13
Figure 2-11, PT Controller Mounting Holes ......................................................................14
Figure 2-12, Surface-mounting the PT-100 Controller .......................................................15
Figure 2-13, Mounting Bracket Dimensions (Each) ...........................................................15
Figure 2-14, PT-100 Controller - System Wiring ...............................................................16
Figure 2-15, Standalone PV System Circuits....................................................................23
Figure 2-16, Ground Fault Label ....................................................................................36
Figure 2-17, Wiring to DC Terminal Block........................................................................37
Figure 2-18, Battery Temperature Sensor .......................................................................39
Figure 2-19, BTS and Battery Cable Hardware Installation.................................................39
Figure 2-20, Auxiliary Relay Connections and Example .....................................................40
Figure 2-21, NETWORK Communication Cable (300V Rated)...............................................41
Figure 2-22, Extension Cable (300V Rated) ......................................................................41
Figure 2-23, Stacking Cable (300V Rated) ......................................................................41
Figure 2-24, Connecting the PT-100 to the Magnum Inverter.............................................42
Figure 2-25, Networking to Accessories (Daisy Chain Configurations) .................................43
Figure 2-26, Networking to Accessories (Star Configurations) ............................................44
Figure 2-27, Wiring Multiple Controllers ..........................................................................47
Figure 2-28, Networking Multiple PT Controller’s ..............................................................48
Figure 2-29, Networking Multiple PT Controller’s with Multiple Inverter’s .............................49
Figure 2-30, Power-up Test Displays...............................................................................51
Figure 3-1, DIP Switch Settings.....................................................................................52
Figure 4-1, Front Panel Display and LED Indicators ..........................................................56
Figure 4-2, Scroll Sequence of Screens...........................................................................57
Figure 4-3, Charge Status Indicators..............................................................................58
Figure 4-4, Hard Fault Conditions...................................................................................60
Figure 4-5, Soft Fault Conditions....................................................................................60
Figure 4-6, Aux Relay Indicator .....................................................................................60
Figure 4-7, SELECT and RESET Pushbuttons....................................................................61
Figure 4-8, I-V Curve ...................................................................................................62
Figure 4-9, Automatic 3-Stage Charging Graph................................................................63
Figure 4-10, Start/Stop Equalize Charge.........................................................................65
Figure 4-11, AFP Test Switch.........................................................................................66
Figure 4-12, BTS Temperature to Charge Voltage Change..................................................67
Figure 4-13, Power Save Indication................................................................................68
Figure 4-14, Viewing Network Address - Stacked Controller...............................................71
Figure 5-1, GFDI Fuse Location (Access Cover Removed) ..................................................81
Figure 5-2, Electronics Section Removal .........................................................................82
Figure 5-3, PT Controller Reset......................................................................................83
Figure 5-4, PT-100’s Firmware Update Connection Port .....................................................84
Figure A-1, Ambient Temperature vs Continuous Current Curve .........................................86
Figure A-2, Output Current vs Battery Voltage Curve........................................................86
Figure A-3, Maximum Power vs MPP Voltage Curve...........................................................87

Page 1
© 2017 Sensata Technologies
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. The PT-100 is simple to use and
reliable, providing maximum flexibility in sizing your PV array and charging different battery types.
1.1 Key Features and Benefits
The PT-100 charge controller includes the following key features and benefits:
• Maximum Power Point Tracking technology for increased PV power output efficiency.
• Continuous charging current up to 100ADC (for 12, 24 or 48V battery systems) and high
input voltage up to 240VDC (Voc).
• PV Ground Fault Detection and Interruption/Indication (GFDI), with pre-fault leakage/
diagnostic metering.
• PV Arc Fault Circuit Interrupter (AFCI) that detects, indicates, and extinguishes series
arcs. Meets the new National Electric Code (NEC) Article 690.11 requirements.
• Multi-stage charging algorithms (automatic bulk, absorption and float, with manual
equalization) to maximize system performance and improve battery life. Suitable for
various types of batteries including flooded, AGM, and GEL batteries.
• Automatic battery temperature compensation using an external temperature sensor
(included) for optimum battery charging, even during extreme temperature changes.
• Extensive electronic protection: Over-temperature protection, power derating when
temperature is high, PV short circuit and high PV input shutdown, output overcurrent
protection and night-time backfeed (reverse current) protection.
• Peak conversion efficiency is higher than 99% (PV In to DC Out).
• Low self-consumption (<4W) - in night-time mode.
• Built-in programmable auxiliary relay for device control (requires remote).
• Internal data logging functionality keeps energy harvest information and battery Ahr/Whr
data up to 255 days (requires ME-ARC or ME-ARTR remote to display).
• Multiple LED indicators and large digital LED screen on front panel provides charger and
fault status information and important system information (PV power input, PV voltage
input, battery voltage and battery current).
• Easy setup with “link” feature to prevent incompatibility issues between the controller
settings and the inverter charge settings—when networked with a Magnum inverter.
• Remain-in-place wiring box design to prevent the removing of conduit/wiring if service
required. Can also be used to pre-install conduit and wires before electronic section install.
• Ability to update software onsite.
• Designed to work with a Magnum Panel (MP) or Mini-Magnum Panel (MMP) - provides
room and access to PV and battery disconnect breakers.
1.2 Regulatory Compliance
The PT-100 has been tested and listed to UL 1741, 2nd Edition (Standard for Charge Controllers,
Converters and Controllers for use in Independent Power Systems) for use in the US; and is
also certified to CSA C22.2 No. 107.1-01 (General Use Power Supplies) for use in Canada. It
has been tested and certified to these product safety standards by Intertek Testing Services
(known as ETL), which is a Nationally Recognized Testing Laboratory (NRTL). NRTL’s are qualified
organizations that meet Occupational Safety and Health Administration (OSHA) regulations to
perform independent safety testing and product certification.

© 2017 Sensata TechnologiesPage 2
Introduction
1PT Mounting Bracket – used to secure the charge controller to a wall or to a Magnum
panel. See Section 2.3 for information on locating and mounting the PT controller.
2PT Display – LED display and indicators illuminate to provide information on charge
controller operation. See Section 4.0 for information on the PT display’s operation.
3Access Cover – under the removable front access cover is the DC wiring terminal, the
switches used for configuring the PT-100, and the cable connection ports to connect
accessories. See Section 2.3.1 for information on how to remove this cover to access the
compartment.
Figure 1-1, Front Features
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.
As shown in Figure 1-1, the front of the PT-100 charge controller is equipped with the following:
12345678910
Access Cover
3
PT Mounting Bracket
1
PT Display
2

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© 2017 Sensata Technologies
Introduction
Figure 1-2, Internal Features
58 476
11
12
The PT controller is equipped with the following features (under the access cover) see Figure 1-2):
4DIP 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.
5ARC 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.
6ARC Fault LED – The red LED flashes to alert you that a series arc has been detected in
the PV system, or the arc-fault test button has been pushed.
7Auxiliary (Aux) Relay Connection Terminal – a 3-port terminal block to allow
connection to an internal aux relay. See Section 2.9 to wire and set up the Aux Relay.
8USB Micro-B Port – this connector port allows you to download and install updated
firmware into the PT-100. See Section 5.8 to update the firmware in your PT-100.
9DC Terminal Block – a 4-port terminal block to connect the PV and battery wires. See
Section 2.7.8 and 2.7.9 for information on wiring to this terminal block.
10 Ground Fault Fuse – this is the fuse for the Ground Fault Detection Interrupter (GFDI)
circuitry. See Section 5.5 for information on replacing this fuse.
11 Ground Busbar – this ground busbar is connected to the PT controller chassis and is used
to tie the DC equipment grounds to a common point (refer to Figure 2-17).
12 Wiring Box – provides the location for making the PV, battery and ground connections, and
includes knockouts to accommodate and secure input and output field wiring. This box has
also been designed to remain in place if the PT-100 requires service (refer to Section 5.6).
13 Dual Stack Ports – these two RJ45 ports are provided to allow multiple controllers to
be connected (or stacked) together. See Sections 2.11 and 4.13 for stacking information.
14 Network Connection Port (green label) – a RJ11 port that allows the PT-100 to network
to a Magnum inverter. See Section 2.10 for information on networking.
15 BTS Connection Port (yellow label) – a RJ11 port that allows the Battery Temperature
Sensor (BTS) to connect to the PT-100. See Section 2.8 for information on the BTS.
9
10 13
15
14

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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.
18 Model/Serial Number Label –This label provides model, UL/CSA listings, serial number
information, date of manufacture, and charge controller specifications. See the PT-100
specifications in Appendix A for more information.
19 Side Knockouts – dual 1” and 1¼” knockouts provided on each side of the DC wiring
box for field wiring. See 2.3.2 before removing knockouts.
Figure 1-3, Side Features
LEFT SIDE RIGHT SIDE
Side
Knockouts
Safety Label 17
Model/Serial
Number Label
18
16 CE Label
19

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© 2017 Sensata Technologies
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. It is the installer’s responsibility to determine which safety codes apply and to
ensure that all applicable installation requirements are followed. Applicable installation
codes vary depending on the specific location and application of the installation.
WARNING: Whenever exposed to sunlight at any intensity, PV modules can generate
current and voltage on its output wires/terminals. Working with PV circuits while the
PV system is exposed to light can result in lethal electric shock. Before making any
connections, de-energize the PV modules, either by removing them entirely from light
or completely covering their front surface with an opaque (dark) material.
CAUTION: Review the “Important Safety Instructions” on pages ii-v before installing
the PT-100.
2.1 Pre-Installation
Before proceeding with the physical installation, read this entire Installation section to determine
how best to install your PT-100 charge controller. Also, review the installation instructions for each
component in the PV installation. The more you thoroughly plan in the beginning and become
familiar with all the components in the installation, the better the chances are that the actual
installation process will occur without incident.
2.1.1 Unpacking and Inspection
Carefully remove the PT-100 charge controller from its shipping container and inspect all contents.
Verify the following items are included:
• PT-100 Charge Controller • 6’ Network Communication Cable (300V)
• Battery Temperature Sensor (15’) • 6’ Extension Cable (300V)
• PT-100 Owner’s Manual • 6’ Stacking Cable (300V)
• Ground Fault Warning Label • Back-mount Bracket (2 pieces) with 4 screws
If items appear to be missing or damaged, contact your authorized dealer or Sensata. If at all
possible, keep your shipping box to help protect your charge controller from damage if it ever
needs to be returned for service.
Important: Save your proof-of-purchase as a record of your ownership; it will be required
if the PT-100 should require in-warranty repair.
Record the unit’s serial number in the front of this manual in case you need to provide this
information in the future. It will probably be easier to record this information now, instead of trying
to gather it after the unit has been installed.
2.1.2 Required Tools and Materials
Hardware/Materials
• Conduit, strain-reliefs and appropriate fittings • 1/4” mounting bolts and lock washers
• Electrical tape • Wire ties
Tools
• #2 Phillips screwdriver • Pliers • Wire strippers
• Drill and drill bits • Pencil or marker • Multimeter
• #2 -3 Slotted screwdriver • Torque wrench • Hammer
• Level

© 2017 Sensata TechnologiesPage 6
Installation
Figure 2-1, Simplified PV System
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.
• PV String Combiner - provides a connection point for multiple PV circuit conductors that need
to be connected. Also provides a convenient location for the required overcurrent protection.
• System Disconnects and OCP (Over-Current Protection) - used to safely isolate the system
equipment from sources of electricity for system maintenance/troubleshooting. The disconnect
can be a circuit breaker, which also provides the required overcurrent protection.
• MPPT Charge Controller (PT-100) - utilizes the available maximum power output from the array
to charge and maintain the battery bank.
• Battery Bank - energy storage to provide power at night or on overcast days when the PV array
cannot generate the power needed.
• Standalone inverter (with an internal battery charger) - converts DC power from the battery
bank to AC (Alternative Current) power, to allow downstream AC loads to be powered.
Note: A standalone inverter is not a grid interactive (also known as utility-interactive) inverter
and it does not have the ability to export (or sell) power back to the utility grid.
Photovoltaic (PV)
Circuits
PV Array
Disconnect
PV String
Combiner
& OCP
External PV-GFP not required,
the PT-100 includes an internal
PV-GFP circuit
PT-100
Charge
Controller
Battery
Disconnect
& OCP
Battery
Bank
Battery
Disconnect
& OCP
Standalone
Inverter/
Charger
AC Loads
Disconnect
& OCP
AC
Generator
Inverter
AC Loads
123456789
PV Array
PV
String
PV
String
PV
String

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© 2017 Sensata Technologies
Installation
Figure 2-2, Removing the Access Cover
2.3 Locating and Mounting the PT Controller
2.3.1 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.
2.3.2 Removing Knockouts
The wiring box on the PT charge controller provides four dual (1” and 1¼”) and three single (½”)
knockouts. These knockouts are provided for routing battery, PV array, BTS, and network cables
into the PT charge controller. Figure 2-4 shows the location of these conduit knockouts.
Before removing the knockouts and mounting the PT controller, think about all the different
wiring requirements and select the knockout closest to the terminal to which the wire connects,
or whichever one works for the way your conduit or field wiring comes in. Refer to Section 2.7.2.
As shown in Figure 2-3, the knockouts can be easily removed by tapping the edge with a straight
bladed screwdriver and a hammer, then twist out with pliers. Do not drill, cut, or punch holes in
the PT charge controller. Use only the knockouts provided. While removing, ensure that no metal
shavings or fragments fall into the wiring compartment.
After removing the knockouts, use bushings or conduits to protect the wiring from damage from
rough edges around the knockout holes.
Figure 2-3, Removing Knockouts
Phillips #8-32 x 3/8”
(9.5 mm) screws (x4)
Access
Cover

© 2017 Sensata TechnologiesPage 8
Installation
Figure 2-4, PT-100 Dimensions and Knockout Locations
FRONT VIEW
Two dual knockouts
inside on wiring box
”
16
15
(3.3 cm) (6.5 cm)
(10.5 cm)
BACK VIEW
”
16
73
(18.3 cm)
LEFT SIDE
VIEW
(3 cm)
”
16
13
(10.3 cm)
B
See Figure 2-6
”
8
13
(3.5 cm)
”
4 1
(6.35 mm)
2 holes total
”
16
73(18.3 cm)
”
8
83(21.2 cm)
1
2
8”(21.6 cm)
(12.7 cm)
5”
(26.4 cm)
RIGHT SIDE
VIEW
B
”
16
29
”
8
41
”
8
15 5
(39.7 cm)
KNOCKOUT TRADE SIZES
(TOTAL):
A = ½” or M20 (x3) B = 1” and 1¼” (x4)
HOLE DIMENSIONS:
A = ” (22.2 mm) B = 1 ” (34.5 mm)
and 1 ” (43.7 mm)
8
/
7
64
/
23
32
/
23
”
8
10 3
TOP VIEW
”
16
13
(6.7 cm)
BOTTOM VIEW
(8.1 cm)
3”
(8.2 cm) (8.2 cm)
4
(3 cm)
”
16
33
AB
AA
1”
(2.5 cm)
1
1”
4
3
B
”
8
25
Overall dimensions (W x H x D):
8½” x 15⅝” x 4⅛”
(21.7 cm x 39.7 cm x 10.5 cm)
Tolerances
Fractions: (±1⁄16”)
Metric: (±.1cm)
”
16
9
”
16
41
(1.4 cm)
BB

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© 2017 Sensata Technologies
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). The charge controller’s full power specifications are
rated with an ambient temperature of 77°F (25°C).
Dry – The area where it is located must be free from any risk of dripping water, or any other liquid
that can enter or fall on the charge controller. The charge controller uses stainless steel and zinc
plated fasteners, a powder-coated aluminum base, and the internal circuit boards are conformal
coated—to help fight the harmful effects of corrosion. However, the controller’s life is uncertain
if used in a corrosive environment, and failure due to corrosion is not covered under warranty.
Info: As a preventive measure to help protect and preclude corrosion to the electrical
ports on the PT-100 controller, silicone dielectric grease compound can be applied into
the RJ11/RJ14 connections (Items 13, 14, and 15 as shown in Figure 1-2). Before
installing the cables, or if leaving any ports open, squirt a liberal amount of silicone
dielectric compound into each port to make an effective moisture and corrosive barrier.
Safe – Keep any flammable/combustible material (e.g., paper, cloth, plastic, etc.,) that may be
ignited by heat, sparks, or flames at a minimum distance of 2 feet (61 cm) from the controller.
Close to the battery bank – The charge controller should be located as close to the batteries as
possible - long DC wires tend to reduce the overall charging performance from the charge controller
to the battery bank. However, the unit should not be installed in the same compartment as the
batteries or mounted where it will be exposed to gases produced by the batteries. These gases are
corrosive and will damage the charge controller; also, if these gases are not ventilated and allowed
to collect, they could ignite and cause an explosion.
Accessible –Do not block access to the front of the charge controller. Allow enough room to view
the charge controller’s display and status indicators, and to remove the access cover to work with
the wiring terminals and connections—as they will need to be checked and tightened periodically.
2.3.4 Mounting Orientation
The PT-100 must be mounted vertically with the wiring box towards the bottom and its heatsink fins
oriented vertically to benefit from convection cooling—DO NOT tilt. The PT-100 has not been tested
nor is approved to be mounted in any other orientation.
Figure 2-5, Mounting Orientations

© 2017 Sensata TechnologiesPage 10
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. This is done by mounting on the side of a Magnum Panel (see Figure
2-8 or by using the supplied wall-mounting bracket to mount against a wall (see Figure 2-10).
The PT-100 controller uses two fans to force air through the controller to help maintain the proper
internal operating temperature. The fans pull in air through the intake vents and blow out air through
the exhaust vents (see Figure 2-6). In order for the PT-100 to provide full output power and to
avoid over-temperature fault conditions, do not cover or block the ventilation openings or install
this charge controller in an area with limited airflow. When mounting the controller, ensure there is
free air flow through the controller and adequate clearance around the rear heatsink fins. To provide
adequate ventilation, allow at the minimum, a clearance of 6” (15 cm) from the bottom surface and
1” (2.5 cm) from the rear and at least 1” (2.5 cm) from one of the side surfaces (see Figure 2-7).
CAUTION: Do not mount this charge controller flush against any surface without
using the wall-mounting bracket that is provided. Damage to the surface and over-
temperature shutdowns may occur, and service life of the controller may be affected.
CAUTION: Do not mount this charge controller in a zero clearance compartment, nor
cover or obstruct the ventilation openings—overheating will result.
Info: If required, the controller may be installed in an enclosure, as long as it is
ventilated with sufficient air flow. The enclosure must have a fresh air intake opening
provided directly to the side of the controller close to the intake vents and an exhaust
opening close to the exhaust vents on the charge controller. This allows cool air from the
outside to flow in and heated air to exit out of the PT-100 and the enclosure.
Figure 2-7, Minimum Mounting
Clearance Requirements
BOTTOM
at least 6"
(15 cm)
REAR
(and at least
one side)
at least 1"
(2.5 cm)
REAR SURFACE
BOTTOM SURFACE
PT-100
Charge
Controller
(side view)
Figure 2-6, Air Flow in and around PT
Air intake
vents
Air exhaust
vents

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Installation
Figure 2-8, Mounting the PT-100 Controller on a Magnum Panel
Charge
Controller
Bracket
PT-100
Charge
Controller
Magnum Panel
(with inverter on top)
Lock nuts
(x3)
close
nipple
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).
2.3.6.1 Mounting the Charge Controller on a Magnum Panel
Use the following steps to mount the PT controller on a Magnum panel:
1. Mount the charge controller bracket (MP-CCB*) on either side of a MP or MMP panel. The
keyhole slots on the back of the controller will be used to attach to the charge control bracket,
see the Section 2.3.6.1.1 to install the bracket on a Magnum panel.
Note *: The MP-CCB is included when you purchase a Magnum Panel (MMP or MP).
2. Remove the 1¼” conduit knockout in the Magnum panel that corresponds with the conduit
knockout in the PT controller.
3. Use a 2” close nipple (with 1¼” openings) for the wire run between the Magnum panel and
the PT controller. Align one end of the nipple with lock nuts and insulator cap through the side
knockout opening in the panel and the other end thru the knockout opening in the controller.
Info: It may take three locknuts on the close nipple to anchor the controller to the
enclosure. An additional locknut may be required between the enclosure and the
controller to act as a spacer. Also, a standard one inch plastic bushing should be used
on the nipple ends to protect the wire insulation as it enters/exits the nipple.
4. Ensure the PT controller is secured to the MP panel.