Plasmatronics PL40 User manual

Rev 6.3.0 12.09.16 PL Reference Manual 1
SOLAR CONTROLLER
PL20
BAT+ SOL- BAT- LOAD-
12-48V 20A CHARGE
PLASMATRONICS
P
L
A
S
M
A
T
R
O
N
I
C
S
BOOST
Ah
N1271
Reference Manual
Plasmatronics PL Series
Advanced Solar Charge Controller

Rev 6.3.0 12.09.16PL Reference Manual
2
Contents
0.1 Introduction.................................................................................... 4
0.2 Additional Installation Notes ..................................................................... 4
0.3 Features..................................................................................................... 5
0.4 Thermal Protection................................................................................... 5
1.0 BATV Menu .................................................................................... 6
Battery Charge Cycle ..................................................................................... 6
1.1 BOST (Boost) ........................................................................................... 6
Returning to Boost state .......................................................................... 6
1.2 Equalise (optional) .................................................................................... 7
1.3 ABSB (Absorption) ................................................................................... 7
1.4 FLOT (Float) ............................................................................................. 7
2.0 CHRG Menu.................................................................................... 8
CHRG ............................................................................................................. 8
CINT .............................................................................................................. 8
CEXT ............................................................................................................. 8
Generator Control ......................................................................................... 8
GSET ........................................................................................................ 8
GMOD ..................................................................................................... 9
GEXD (Generator Exercise)................................................................... 10
GDEL (Generator changeover delay) .................................................... 10
Generator Example ................................................................................ 10
Generator Start Relay Wiring.................................................................. 11
3.0 LOAD Menu ................................................................................. 12
LOAD ........................................................................................................... 12
LINT ............................................................................................................. 12
LEXT ............................................................................................................ 12
Low Battery Disconnect (LSET, LOFF, LON, LDEL)..................................... 12
4.0 IN Menu ........................................................................................ 13
IN ................................................................................................................. 13
IN/INT .......................................................................................................... 13
IN/EXT ......................................................................................................... 13
5.0 OUT Menu .................................................................................... 13
OUT.............................................................................................................. 13
OUT/INT ..................................................................................................... 13
OUT/EXT .................................................................................................... 13
6.0 DATA Menu (Retrieving Performance Data) .............................. 14
6.1 & 6.2 VMAX & VMIN ............................................................................. 14
6.3 FTIM (Float time Display) ....................................................................... 14
6.4 SOC (State of Charge Display) ............................................................... 15

Rev 6.3.0 12.09.16 PL Reference Manual 3
6.5 TEMP (External Battery Temperature Sensor Display) .......................... 16
Setting Lockout .................................................................................. 16
6.6 SOLV (Solar Voltage Display) ................................................................. 16
6.7 HIST (History display) ............................................................................ 16
7.0 SET menu ..................................................................................... 17
7.1 TIME ....................................................................................................... 17
7.2 VOLT ...................................................................................................... 17
7.3 PROG (Adjusting Regulation Settings) .................................................... 17
Program Function Table (Generic Programs) ......................................... 17
Program Description .............................................................................. 17
Settings Used in Programs 0-3 ............................................................... 18
Settings for Program 4 ........................................................................... 18
7.4 REG menu (Customising Regulation Settings) ........................................ 19
7.4.1 HYST (Hysteresis Value)................................................................ 19
7.4.2 Charge Current Limit ................................................................... 20
7.4.3 TCMP (Temperature compensation) ............................................ 20
Connecting a Temperature Sensor .................................................. 21
7.5 MODE Menu (Adjusting Configuration Settings) ................................... 22
7.5.1 & 7.5.2 LSET & GSET ................................................................... 22
Diversion Control............................................................................. 24
7.5.3 BSET: Configuring B- Sense Input .................................................. 24
7.5.4 BAT2 - Second battery control ..................................................... 26
7.5.5 PWM and Slow Switching .............................................................. 27
7.5.6 BCAP ............................................................................................ 28
7.5.7 ALRM ............................................................................................ 28
7.5.8 RSET .............................................................................................. 28
7.6 EVNT Menu (Event Control) ................................................................. 29
Using the Event Controller .................................................................... 29
Examples: ............................................................................................... 33
A.0 Appendices .................................................................................. 34
A.1 Accessories ............................................................................................. 34
A.2 Specifications on PL20, 40, 60, 80 .......................................................... 35
A.3 ‘Catch diode’ protection ........................................................................ 35
A.4.1 Block Diagram of PL20/40 Hardware ................................................. 36
A.4.2 Block Diagram of PL60/80 Hardware ................................................. 36
A.5 Thermal derating ................................................................................... 37
A.6.1 System Settings .................................................................................... 38
A.6.2 History DATA ...................................................................................... 39
A.7.1 Programs 0-3 Menu System................................................................. 40
A.7.2 Program 4 Menu System (for custom settings).................................... 41
A.8 Mechanical Information........................................................................... 43

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0
3
0.2 Additional Installation Notes
Ensure that you have followed the installation
instructions on pages 3-5 of the User Guide.
The PL can be used for system voltages of up
to 48V. It is safe to connect the power before
setting the system voltage, even with a 48 volt
battery.
The PL is not an MPPT or voltage converter.
It needs a solar array with a maximum power
point voltage (Vmpp) of approximately 17V per
12V or nominal system voltage.
Always mount the PL vertically with clear airflow
around the fins. In hot conditions, do not put the
PL in a sealed enclosure, as this will restrict the
airflow around it. Do not install the PL in direct
sunlight in hot conditions - the heatsink may
reach over 70°C in some environments.
The PL is specified for up to 50°C ambient
temperature. If the LCD display reaches 60°C
it will darken and may become unreadable,
however it will return to normal when it cools
down.
0.1 Introduction
Please read the User Guide before reading this
manual.
In most cases, the User Guide provides all the
information needed for effective installation of
the PL, and there is no need for the user to read
this Reference Manual.
However, in some cases, users with a good
understanding of power regulation may wish to
customise individual settings or adjust some of
the PL’s advanced features. This manual describes
the procedures for making these adjustments.
Please note that this manual assumes more
technical knowledge than the User Guide.
If you are in any doubt, it is recommended you do not
adjust the advanced settings described in this manual.
Incorrect adjustment may reduce the effectiveness of
your PL and could damage your battery.
All voltage values used in this manual assume
a 12V system. Scale voltages for other system
voltages (e.g. 24V system = voltages x 2, 48V
system = voltages x 4).

Rev 6.3.0 12.09.16 PL Reference Manual 5
0
0.3 Features
The PL series of solar controllers are exceptionally
versatile. They give the user unparalleled capability
to adjust the function of the controller and to
monitor the performance of the energy system.
To cater for both non technical and technical users,
the PL has four preset programs which can be used
without needing to understand the details of its
operation. For those with a good understanding of
power regulation, there is another program, which
allows all the settings to be adjusted if required.
Once the program has been selected, it is
possible to disable any further adjustment. This
prevents unauthorised adjustment of settings.
Although the PL is primarily a device to control the
charging of batteries from solar electric (photovoltaic)
panels, it can also be used with other energy sources
such as wind, microhydro and fuel driven generators.
The PL can support a variety of regulation
methods. It supports slow speed switching and
fixed frequency pulse width modulation (PWM)
control in series and diversion modes.
There is provision for a temperature sensor to
be attached. There is an input for measuring
external voltages. A communications interface
is provided for accessories including remote
shunt adapters (PLS2), an RS232 adapter to
communicate with a computer/modem (PLI),
and a PLA unit which provides additional alarm
outputs and syncronisation of multiple regulators,
as well as an RS232 output.
The PLI and PLA allows remote monitoring and
adjustment. Custom settings can be stored on a
computer and uploaded into the PL controller.
Data from the PL can be downloaded into the
computer and displayed easily.
Low battery voltage load disconnection is
provided, as are an alarm, facility to control the
charging of a second battery bank, control for
a back up generator and an event controller
which can be used to control lights, pumping,
waste energy use and other timer functions. A
temperature sensor can be added to correct the
regulation voltages for battery temperature.
The PL controller can have external current
shunts attached and control larger systems
through external switch blocks or relays.
0.4 Thermal Protection
The PL has a temperature sensor on the circuit
board. The function of this sensor is to tell the
PL how hot it’s own circuit board is so that it can
reduce the charge current (the major heating
source) in order to protect against overheating.
It’s virtually impossible for a correctly installed PL
in good order to overheat.

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Fig. 1B - The Battery Charge Cycle
1
1.0 BATV Menu
The BATV screen, shown at power-up,
gives the real-time battery voltage.
Note: There is a software version number
shown on the display for approximately 1
second each time the PL is turned on - this
is not a voltage.
Long push on BATV screen will display
current regulation cycle state.
The Battery Charge Cycle
The PL’s sophisticated regulation system is
designed to keep the battery fully charged
without overcharging it.
To achieve this, it uses a charge control process
with three main states. These states are Boost,
Absorption and Float. The PL also uses a fourth
state from time to time, called the Equalisation
state (See fig 1B.)
1.1 BOST (Boost)
In the boost stage, all the charge current available
is used to charge the battery. As the battery
charges, its voltage rises. When the voltage
reaches the boost maximum voltage (BMAX) and
remains there for 3 minutes, the controller will
automatically advance to the absorption stage.
Returning to Boost state
To get this charge cycle to repeat, the PL must
return to the boost state. There are three ways
that it can do this.
a. Low Battery Voltage
If the battery voltage falls below the boost return
voltage BRTN for more than 10 minutes, then
the PL will switch back into the boost state. The
delay is necessary to prevent large short term
loads causing unnecessary returns to Boost state.
b. Programmed boost cycles (optional)
The PL will automatically do a boost cycle after a
set number of days (BFRQ), regardless of battery
voltage.
c. Manual boost
The user can manually set the PL into the boost
state (or any of the regulation states).
To manually advance to the next state, do a
long push on BATV. This will show the current
regulator state. (BOST=Boost, EQUL=Equalise,
ABSB=Absorption, or FLOT=Float). A long-
push on that state will manually advance the PL
into the next state. Or, to return to the BATV
screen without changing the state, do a short
push.
Note: if ETIM is 0, then the Equalise state will
be bypassed. If ATIM is 0, then the Absorb state
will be bypassed.
BATTERY VOLTAGE
TIME
BOOST EQUALISATION ABSORBTION FLOAT BOOST
BRTN
FLTV
ABSV
EMAX
BMAX
ETIM
ATIM
Fig. 1B - The Battery Charge Cycle
BOST EQUL ABSB FLOT
BATV
CHRG
LOAD
IN
OUT
DATA
SET
Fig. 1A - The BATV Menu Structure

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1
On the BOST and FLOT displays, the battery
voltage is shown. On the EQUL and ABSB
displays, the time on the equalisation or
absorption timer is displayed. When this time
gets up to the set time (ETIM or ATIM) the PL
will advance to the next state. Remember that
the timers will stop if the voltage falls below the
relevant set point.
1.2 Equalise (optional)
Many battery manufacturers recommend
that the battery bank be given an overcharge
occasionally. This is designed to equalise the
voltages and specific gravities of all the cells in
the bank by bringing them all up to full charge
and stirring up the electrolyte in the liquid cells
by gassing to reduce stratification.
The PL supports an automatic programmed
equalisation. This state allows the battery
voltage to rise until it gets to the equalisation
voltage EMAX if possible and then remain at this
voltage for the set equalisation time ETIM. This
equalisation is done every EFRQ days. (Typically
30-60 days). Equalisation will begin at 9am on the
appropriate day. If ETIM is 0, then equalisation
will not occur.
To prevent the controller being trapped in equalise
mode for a long time because there is inadequate
charge current to reach the equalise voltage, the PL
terminates equalise after 4 days.
1.3 ABSB (Absorption)
In this state, the PL tries to keep the battery
voltage constant while the last part of the battery
charging occurs. This prevents excessive gassing
which occurs at high cell voltages. The PL will
keep the battery voltage at the absorption
voltage ABSV until it has been at this voltage for
the absorption time ATIM. If there is a cloudy
period and there is insufficient charge current to
keep the voltage up to ABSV, then the absorption
timer will stop and resume when the voltage
comes back up to ABSV. When the absorption
time is finished, the PL advances to the Float
state.
1.4 FLOT (Float)
In this state, the battery has been fully charged.
The charge current is now used to keep the
battery voltage at a level which maintains full
charge. This voltage (FLTV) should be below the
gassing voltage to avoid excessive electrolyte
loss. If charge is drawn from the battery, the PL
will allow charging to resume until the battery
returns to FLTV.

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BATV
CHRG
LOAD
IN
OUT
DATA
SET
CINT CEXT
GSET Toggle function status on / off
GMOD Set generator control mode
G ON G ON G ON Set V / SOC% to start generator
GOFF Set SOC% to stop generator
GOFF GOFF Set V to stop generator
GDEL GDEL Set delay before on/off change
SOC% SOC% State Of Charge (SOC) Long push to reset (100%)
GEXD GEXD GEXD Set number of days between generator exercises
GRUN GRUN GRUN GRUN Set length of generator exercise
GDAY GDAY GDAY View/change # days since last exercise
(or run time if generator running)
0 or 4 1 or 5 2 or 6 3
Fig. 2A - Generator Control Menus (PROG=4 only)
2
2.0 CHRG Menu
CHRG
The CHRG screen gives the real-time total
charging current (Amps). This total is the sum
of solar charge current (CINT) and any external
charge current (CEXT) measured using an
optional shunt and PLS2.
CINT
From the charge screen, a long push displays
CINT (Charge Internal). This is the real-time
solar charging current in amps.
CEXT
From the CINT screen, a short push displays
CEXT (Charge External). This is the real-time
external charging current measured using an
optional shunt and PLS2.
Generator Control
The PL has a comprehensive generator
controller built in. It works in a similar way
to Low Battery Disconnect, using an internal
function. It is designed to give a run or stop
signal to an electronic start generator. It does not
handle the actual generator start-up sequence -
this should be done by the generator itself.
GSET
In the GSET screen, a long push will manually
change the state of the generator output (will
not work if in ‘quiet-time’ 9pm-9am). The
GEN indicator at the bottom of the screen is
visible when the generator function wants the
generator to be running.
Note - do not confuse the GSET described in Figure
2A with the screen of the same name described in
Section 7.5.2. under the SET Menu.

Rev 6.3.0 12.09.16 PL Reference Manual 9
Quiet Time M* No Quiet Time
GMOD: 0 1 2 3 4 5 6 Name Description Range
• • GON Set V to start generator 10-12.5V
• • • • GON Set SOC% to start generator 0-99%
• • • • GOFF Set V to stop generator 11.0-16.5V
• • GOFF Set SOC% to stop generator 1-125%
• • • • GDEL Set delay before on/off change 1-15 min
• • • • SOC% Current SOC%
Long push to reset to 100%
0-127%
• • • • • • GEXD Set number of days between
generator exercise
2-60 days
• • • • • • • GRUN Set length of generator exercise 0-4.0 hrs
• • • • • • GDAY View/change # of days since
last exercise
2-60 days
• = Active Parameter for relevant generator mode (GMOD)
*M = Manual
GMOD = GMOD Settings
Mode# Description
0. Turn on when battery voltage falls to G
ON for GDEL minutes. Turn off when the
voltage rises to GOFF for GDEL minutes.
Quiet time applies.
1. Turn on when the State of Charge (SOC%)
falls to G ON % of the battery capacity.
Turn off when the voltage rises to GOFF
for GDEL minutes. Quiet time applies.
2. Turn on when SOC % falls to G ON%.
Turn off when SOC% rises to GOFF%.
(GOFF% can be set to greater than 100% to
allow some overcharge.) Quiet time applies.
3. Manual start. When started (in the GSET
screen) the generator will run for GRUN hours.
4. No quiet time. Turn on when battery
voltage falls to G ON for GDEL minutes.
Turn off when the voltage rises to GOFF
for GDEL minutes.
5. No quiet time. Turn on when the State
of Charge (SOC%) falls to G ON % of the
battery capacity. Turn off when the voltage
rises to GOFF for GDEL minutes.
6. No quiet time. Turn on when SOC % falls
to G ON%. Turn off when SOC% rises to
GOFF%. (GOFF% can be set to greater
than 100% to allow some overcharge.)
2
GMOD
Generator control can operate in four different
ways:
- Voltage ON, Voltage OFF
(ON and OFF via voltage)
- SOC ON, Voltage OFF
(ON via SOC and OFF via voltage)
- SOC ON, SOC OFF
(ON and OFF via SOC)
- and Manual
See table for detailed description.
The generator mode is selected in the GMOD
screen and can be 0-6.
Quiet time: In modes 0,1 & 2, the generator is
not allowed to operate from 9pm until 9am so as
to enforce a ‘quiet time’.
Modes 4-6 are the same as modes 0-2 except
that there is no quiet time.
Mode 3 is manual.

Rev 6.3.0 12.09.16PL Reference Manual
10
2
GEXD (Generator Exercise)
To prevent the generator from seizing up, it
is good practice to exercise the generator
periodically. The PL supports this with an
automatic generator exercise function, which will
turn on every GEXD days at 9am. The number
of days since the last exercise is shown on the
GDAY screen. The generator will run for GRUN
hours. When running, the elapsed time is shown
on the GTIM screen. Both GDAY and GTIM can
be adjusted.
Note:
1. There is no generator exercise when GMOD = 3
(manual start).
2. GSET toggle does not work during generator
exercise
3. A small amount of overcharge will occur if
battery is already fully charged. Use a low GRUN
value if this is of concern.
GDEL (Generator changeover delay)
A programmable delay (in minutes) is used to
prevent any large transient loads from triggering
a generator change of state (on/off). Default
programs are set to 10 minutes. Note: Do not confuse GSET (CHRG menu) and
LSET (LOAD menu) with screens of the same
name in the SET/MODE menu. They perform
different functions.
Generator Example
The generic programs (PROG=0-3) use
voltage driven generator control (GMOD=0).
See “settings used in Programs 0-3” for on-off
voltages etc.
If you want something different, eg SOC%-
triggered generator on, voltage-triggered
generator off, and no quiet time, you would set
up the PL as follows:
PROG = 4 Allows changing of generator
functions etc
GMOD = 5 SOC % ON, Voltage OFF,
no quiet time
CHRG menu:
Set GON, GOFF, GDEL, SOC%
GEXD, GRUN as required
SET/REG menu: Check these settings are
correct for your battery type
SET/MODE menu:
LSET = 2
or
GSET = 2
LSET if using LOAD - terminal
for relay
GSET if using ‘G‘ terminal for
relay

Rev 6.3.0 12.09.16 PL Reference Manual 11
NC
NO
Battery Positive
+
PL60/PL80 Generator start relay wiring
PL60/80
SOL- BAT- BAT+ SOL+ Load+ Load-
G Contacts
(300mA max)
-
Battery Negative
}To Generator
Start input
Optional Series Resistor:
A series resistor can be
used to drop the voltage
across the relay to lower
than the battery voltage.
You need to calculate
resistor value/power.
Fig. 2C - PL60/PL80 Generator
start relay wiring
Catch
Diode
must
be
tted
NC
NO
Battery Positive
+
PL20/40 Generator start relay wiring
PL20/40
-
Relay
}To Generator
Hint:
Note:
Start input
(Typically contact closure
starts generator, but
consult generator manual)
The relay can be replaced
with a suitable visual
indicator (LED + resistor
or a small lamp) to show
the user when to start the
generator.
Max current = 120mA
(Typically contact closure
starts generator, but
consult generator manual)
Since the ‘G Contacts’ are
voltage-free, the relay can
be switched in the negative
or positive wire (negative
wire switching shown)
Many installations won’t require
an external relay and can be
switched directly from the‘G’
outputs (max current 300mA).
Use an external relay if unsure.
B+ S- B- L-
B- T+ T- G
120mA max
Optional Series Resistor:
A series resistor can be
used to drop the voltage
across the relay to lower
than the battery voltage.
You need to calculate
resistor value/power.
(eg 1N14007)
Fig. 2B - PL20/40 Generator
start relay wiring
2

Rev 6.3.0 12.09.16PL Reference Manual
12
Name Description Range
LOFF Set voltage at which load
disconnects
10.0-12.5 V
LON Set voltage at which load
reconnects
11.0-16.0 V
LDEL Set delay before
switching on/off
0-15 min
BATV
CHRG
LOAD
IN
OUT
DATA
SET
LINT LEXT
LSET Toggle low battery
LOFF Set voltage at which
L ON Set voltage at which
LDEL Set delay before
load disconnects
load reconnects
disconnect status on/off
switching
Fig. 3A - LOAD Menu
3
3.0 LOAD Menu
LOAD
The LOAD screen gives real-time total load
current (in Amps). This total is the sum
of load current being used by equipment
connected to the LOAD- terminal and any
external load current measured using an
optional shunt and PLS2.
LINT
From the LOAD screen, a long push displays
LINT (Load Internal). This is the real-time load
current being used by equipment connected to
the PL’s LOAD- terminal.
LEXT
From the LINT screen, a short push displays
LEXT (Load External). This is the real-time
external load current measured using an optional
shunt and PLS2.
Low Battery Disconnect
(LSET, LOFF, LON, LDEL)
To prevent battery damage due to over-
discharge, the PL has an internal function which
can be set to turn off either the LOAD- terminal
or the “G” terminal if the battery voltage falls too
low. (This feature is also sometimes referred to
as “Load Control”, LBD and LVD)
If correctly configured, equipment connected to
the battery (the “load’) will be turned off when
the LOAD- or “G” terminal is turned off. Once
turned off, the load will not be reconnected
until the voltage rises enough to indicate some
recharge has taken place.
This feature is optional, and can be disabled
either by connecting the user load directly to the
battery, or by setting the parameters to ensure
the low battery disconnect function never turns
on.
The LOAD indicator at the bottom of the screen
is visible when the low battery disconnect
function wants to disconnect the load. (Note
that other settings can override the function, so
the LOAD indicator does not necessarily mean
that the power actually has been disconnected
from the load.)
The Low Battery Disconnect function can also
be toggled manually by a long push when in LSET
menu (see Figure 3A).
The low battery disconnect function can be set
to use the LOAD- terminal, or the G (General
Purpose Output) terminal to disconnect the
load. Its operation can also be reversed, i.e.
it can turn on the terminal when the function
decides the load should be disconnected. This
can then be used as a low battery alarm or to
drive a relay to turn off other loads.
DO NOT CONNECT AN INVERTER OR
ANOTHER BATTERY TO THE LOAD-
TERMINAL(S). The terminal(s) are rated
at 20A on the PL20, 7A on the PL40, 30A
on the PL60 and 40A on the PL80. Most
inverters draw larger currents than this and
have their own low battery cut off circuitry
anyway.

Rev 6.3.0 12.09.16 PL Reference Manual 13
INT EXT
Clear Clear
BATV
CHRG
LOAD
IN
OUT
DATA
SET
INT EXT
Clear Clear
BATV
CHRG
LOAD
IN
OUT
DATA
SET
Fig. 4A - IN Menu Fig. 5A - OUT Menu
4
5
4.0 IN Menu
IN
The IN screen gives a running total of Amp hours
(Ah), or energy, that has been input during the
day (since midnight). This total is the sum of Solar
Ah collected and any external Ah input that was
measured using an optional shunt and PLS2.
IN/INT
From the IN screen, a long push displays INT
(Internal Ah IN). This is the running total of Ah
collected from the solar over the day (since
midnight). A long push will clear the INT running
total.
IN/EXT
From the INT screen, a short push displays EXT
(External Ah IN). This is the running total of
external Ah input and measured using an optional
shunt and PLS2. A long push will clear the EXT
running total.
5.0 OUT Menu
OUT
The OUT screen gives a running total of Amp
hours (Ah), or energy, that has been used during
the day (since midnight). This total is the sum of
Ah used by equipment connected to the LOAD
terminal and any external Ah measured using an
optional shunt and PLS2.
OUT/INT
From the OUT screen, a long push displays INT
(Internal Ah OUT). This is the running total of Ah
used by equipment connected to the regulator’s
LOAD- terminal. A long push will clear the INT
running total.
OUT/EXT
From the INT screen, a short push displays EXT
(External Ah OUT). This is the running total of
external Ah used and measured using an optional
shunt and PLS2. A long push will clear the EXT
running total.

Rev 6.3.0 12.09.16PL Reference Manual
14
Thin arrow = short push
Thick arrow = long push
BATV
CHRG
LOAD
IN
OUT
DATA
SET
DAY 1 IN OUT VMAX VMIN FTIM SOC NEX T BACK EXIT
DAY 2 DAY 30 DATA
VMAX VMIN FTIM SOC TEMP SOLV HIST
DAY 2 IN OUT VMAX VMIN FTIM SOC NEX T BACK EXIT
DAY 3 DAY 1 DATA
DAY 3 IN OUT VMAX VMIN FTIM SOC NEX T BACK EXIT
DAY 4 DAY 2 DATA
DAY 30 IN OUT VMAX VMIN FTIM SOC NE XT BACK EXIT
... ... ... ... ... ... ...
DAY 1 DAY 29 DATA
Long push to reset
(100%)
Toggle setting lockout
(’A’ showing means
settings adjustable)
Fig. 6A -The DATA Menu Structure
6
6.0 DATA Menu (Retrieving Performance Data)
A long-push on DATA shows performance
information for the current day.
The screens in the DATA menu have the
following meanings:
At midnight, VMAX, VMIN, FTIM, SOC, IN and
OUT are stored in the history data and cleared
from the current day readings.
6.1 & 6.2 VMAX and VMIN
VMAX and VMIN respond very slowly to
changes in battery voltage. This allows them to
ignore short term voltage fluctuations. (Warning:
at reset or initial start up, they can take up to 40
minutes to reach the correct value.)
6.3 FTIM (Float time Display)
FTIM indicates the time of day that the regulator
changed from the ABSB (Absorption) state to
the FLOT (Float) state.
Note: This time will only be recorded if the PL
has done a complete charge cycle, ie.
Boost →Equalise →Absorption →Float
(if selected)
VMAX maximum battery voltage since midnight.
VMIN minimum battery voltage since midnight.
FTIM time of day the regulator entered the
Float state.
SOC estimated state of charge of the
battery based on the amp hours in and
the amp hours out. A very rough ‘fuel
gauge’ -see below for further details.
TEMP
temperature being sensed by the external
battery temperature sensor (if attached).
SOLV solar panel voltage (open circuit)
HIST entry point for history data.

Rev 6.3.0 12.09.16 PL Reference Manual 15
6
6.4 SOC (State of Charge Display)
SOC (State Of Charge) should be read as a
percentage estimate of how full the battery is.
The estimate is based on the amp hour balance
counter. This counter keeps a running balance
of amp hours in vs amp hours out. The SOC
display shows this balance as a percentage of the
battery size. Note that all system currents must
be monitored by the PL and the battery capacity
(BCAP) must be entered by the installer for SOC
to be meaningful.
Over time, the amp hour balance counter
will drift out of line with the real battery
state of charge. To realign the counter the PL
automatically makes two corrections:
1. When the PL state changes from Absorb to
Float AND the charge duty cycle is less than
25%, SOC is reset to 100%.
2. SOC is capable of reading more than 100%,
however as soon as 1Ah of discharge is
recorded it will be set back to 100%, thus
discarding any surplus amp hours. These amp
hours were really put into the battery, but the
battery cannot be more than 100% full. The
difference is mostly the inherent loss in the
battery. The battery is never 100% efficient.
Note: A long push on the SOC screen will reset
the unit to 100%.
The SOC figure should be treated with caution,
as there are several reasons that it may be
inaccurate:
• The PL does not automatically have
knowledge of the whole system. It only
knows what you tell it. For SOC to work at
all, the PL must be measuring all charge (Ah
in) and discharge (Ah out). If the battery can
charge or discharge without the PL knowing,
SOC will not be meaningful.
• Variations in charge efficiency mean SOC will
tend to be a little optimistic.
• The effective capacity of the battery reduces
with age. BCAP should be reduced in older
batteries to adjust for this.
• When you set up BCAP on installation, you
should choose your best guess of the batteries
actual capacity when used in the way you
intend to use it. For example, if you think the
battery will mostly be charged and discharged
at around the 100h rate (C/100) you should
set the capacity of you battery at the 100h
rate from the manufacturer’s literature. If
you expect the battery to be used at various
charge and discharge currents, try to estimate
an average. In many systems it is more
accurate to use the C/20 rate.
• Battery self discharge and variations in
temperature will also cause some inaccuracy.
SOC (%) = BCAP
Ah balance counter x 100
Ah balance counter=running balance of Ah IN vs Ah OUT
BCAP=battery capacity Ah input set upon installation

Rev 6.3.0 12.09.16PL Reference Manual
16
Fig. 6C - Lockout link on early PLs
6
Fig. 6.5A - Toggle setting lockout
6.5 TEMP (External Battery
Temperature Sensor Display and
Setting Lockout)
In addition to showing the external battery
temperature (if a sensor is attached), this menu
is also used to adjust Setting Lockout (see figure
6.5A).
Setting Lockout
In some cases it is desirable to restrict the ability
to adjust settings, so as to prevent unwanted
tampering. Setting lockout is done via the TEMP
screen under the DATA menu. (The TEMP
screen shows the battery temperature if the
optional external temperature sensor is installed,
or “0.0” if it’s not.)
To disable settings, long push on the TEMP
screen, the “A” indicator will disappear. (A useful
memory aid is to consider that “A” stands for
“Adjust” on this screen.). Note that the same
“A” indicator is used on other screens to mean
Amps.
To enable adjustment of settings again, long
push on the TEMP screen again. If you have
successfully enabled settings adjustment, the “A”
will reappear while TEMP is showing.
Lockout on early regulators
Note that some very early models of the PL had
a physical link under the cover, which achieved
the same purpose. If your PL is an early model
and you are still unable to change your settings
after following the above procedure, you may
need to obtain the settings lockout link. Contact
your dealer.
If you wish to obtain the link yourself, the Part#
is Farnell 510-920 (2mm pitch).
You will need to temporarily disconnect the
cable of any accessory installed in the system.
The link is installed on the 8 way pin header
under the lid of the PL controller (under lower
left corner of display).
6.6 SOLV (Solar Voltage Display)
This screen displays the solar panel voltage (open
circuit).
Note that the charge current to the battery is
turned off while the PL is displaying this screen,
but if the view is left on the SOLV screen, the
panels will be reconnected when the screen goes
to sleep (failsafe) after 16 minutes.
6.7 HIST (History display)
Six pieces of data are recorded each day. These
are IN, OUT, VMAX, VMIN, FTIM and SOC.
These records are available for the past 30 days.
At the start of each day record is the DAY
screen. This shows which day’s data you are
looking at (DAY 1 = yesterday, DAY 2 = the day
before yesterday, etc.)
For help with navigating through the History,
refer to Fig.6A. Note that a short push on the
EXIT screen will take you back to the beginning
of that day’s record.
BATV
CHRG
LOAD
IN
OUT
DATA
SET
VMAX VMIN FTIM SOC TEMP SOLV HIST
Toggle setting lockout
("A" showing means setting adjustable)
NOTE: Incorrect installation can
permanently damage your PL
Controller. Do not use a metal tool.

Rev 6.3.0 12.09.16 PL Reference Manual 17
Set
time
Set
battery
voltage
TIME VOLT PROG REG MODE EVNT
Set
program
BATV
CHRG
LOAD
IN
OUT
DATA
SET
Fig. 7A - The SET Menu
7
7.0 SET menu
7.1 TIME
A 24hr format is used for system time, with a
resolution of 6 minutes (0.1 hours).
Note: Removing power to the regulator (ie
turning it off) will reset the system time to
0.0hrs (midnight). You will need to re-enter the
current time whenever the regulator is restarted.
Incorrect system time will result in misleading
history data since this is stored at midnight of each
day. Generator quiet-time and time-driven event
control will also be affected.
7.2 VOLT
Set VOLT to the nominal system voltage for your
installation.
This setting determines the regulation and
control voltage set-points for your system.
Note: Your regulator will not be damaged if
the voltage is set incorrectly, however you
would probably damage your battery (under-
or overcharge) if this setting is in error for any
length of time.
7.3 PROG (Adjusting Regulation
Settings)
The PL comes with a number of preconfigured
programs, which are set up for generic batteries.
For custom installations, one program (Program 4)
allows the user to adjust each setting individually.
If you find you are unable to change your settings, it
may be because the “lockout” setting is activated.
This setting is designed to prevent unwanted
tampering— please see the “Setting Lockout”
information in section 6.5.
Program Function Table
(Generic Programs)
Program#: 0 1 2 3
Batt Type: Flooded Sealed Flooded Sealed
LOAD- Term
Functions:
No Night Light Night Light
Low Battery Disconnect
Low Battery Disconnect is enabled for Programs 0-3.
Programs 2&3 turn on the LOAD- terminal at night.
Program Description
PROG 0: Use with liquid electrolyte lead acid
(ie. flooded) batteries. The LOAD- terminal is
set to turn off when the battery is low. (Also
known as Low Battery Disconnect).
PROG 1: Use with Sealed batteries (AGM or
Gel) . The LOAD- terminal is set to turn off
when the battery is low. (Also known as Low
Battery Disconnect).
PROG 2: Use with liquid electrolyte lead acid
batteries (ie. flooded). The LOAD- terminal
is set to turn on at night and can be used
for night lighting, but will turn off when the
battery is low (Low Battery Disconnect).
PROG 3: Use with Sealed batteries (AGM or
Gel) . The LOAD- terminal is set to turn on at
night and can be used for night lighting, but will
turn off when the battery is low (Low Battery
Disconnect).
PROG 4: Enables customised adjustment of all
settings.
Installation instructions for programs 0-3 are on
pages 8-9 of the User Guide.

Rev 6.3.0 12.09.16PL Reference Manual
18
CHRG Setting for program number
Parameter 0 1 2 3
GMOD 0
G ON (V) 11.5
GOFF (V) 13.8
GDEL (Min) 10
GEXD (Day) 30
GRUN (Hr) 1.0
LOAD Setting for program number
Parameter 0 1 2 3
LOFF (V) 11.3
L ON (V) 12.8
LDEL (Min) 10
SET/REG Setting for program number
Parameter 0 1 2 3
BMAX (V) 15.0 14.2 15.0 14.2
EMAX (V) 16.0 14.0 16.0 14.0
ETIM (Hr) 1.0 0 1.0 0
EFRQ (day) 45
ABSV (V) 14.0
ATIM (Hr) 2.0
FLTV (V) 13.8
HYST (V) 0.4
BRTN (V) 12.3
CHRG (A)
PL20 20
PL40 40
PL60
PL80
60
80
BFRQ (Day) 15
TCMP 0
SET/MODE Setting for program number
Parameter 0 1 2 3
LSET 1 1 4 4
GSET 2 2 9 9
BSET 0 0 2 2
BAT2 (V) 14.0
PWM 1
ALRM (V) 11.4
SET/EVNT Setting for program number
Parameter 0 1 2 3
STRT 12
TIME (Hr) 0
STOP 12
TIME (Hr) 25.0
EMOD 2
TMOD 0
7
Settings Used in Programs 0-3
When programs 0-3 are selected, the PL
automatically uses the values below in its
regulation.
The voltage settings are shown correct for 12V
operation. For higher voltages, scale these up
(eg. for a 24V system, multiply each voltage
figure by 2.)
Settings for Program 4
If program 4 is selected, then all menu items can
be accessed.
After TIME, VOLT and PROG, there are entry
points for three further sub menus:
The REG menu allows you to customise the
regulation settings for the PL (see below for
details).
The MODE menu allows you to adjust other
configuration options for the PL.
The EVNT menu allows entry of settings for the
event controller.

Rev 6.3.0 12.09.16 PL Reference Manual 19
BATV
CHRG
LOAD
IN
OUT
DATA
SET
TIME VOLT PROG REG MODE EVNT
BMAX
EMAX
ETIM
EFRQ
ABSV
ATIM
FLTV
HYST
BRTN
CHRG
BFRQ
TCMP
Set max boost voltage
Set max equalisation voltage
Set equalisation time
Set # days between eq.cycles
Set absorption voltage
Set absorption time
Set oat voltage
Set hysteresis
Set boost return voltage
Set charge current limit
Set max days to between boost cycles
Set temp compensation prole
Fig. 7.4A - Regulation Settings (Program 4 only)
Name Description Range
BMAX Maximum voltage in boost
mode
13.5-16.5V
EMAX Equalisation voltage 14.0-17.0V
ETIM Equalisation time 0-2.0 hours
EFRQ Number of days between
equalisation cycles
20-150
ABSV Absorption voltage 13.5-15.5V
ATIM Absorption time 0-4.0 hours
FLTV Float voltage 13.0-15.0V
HYST Hysteresis used when not
in PWM mode
0.1-1.0V
BRTN Voltage below which
return to Boost mode
occurs
11.0-13.0V
CHRG Charge current
limit
PL20 0.5-20A
PL40 0.5-40A
PL60 0.5-60A
PL80 0.5-80A
BFRQ Maximum number of days
between boost cycles
1-20
TCMP Selection of temperature
compensation profile (see
following)
0-8
7
7.4 REG menu (Customising
Regulation Settings)
[PROG=4 only]
To adjust the regulation settings, long-push on “SET”,
short-push to “REG”, and long-push (see figure 7.4A).
The settings are described below for 12V systems.
For other voltages the range can be scaled from
this. (eg. for a 24V system, multiply all voltages by
2.)
SET/REG Submenu Summary: 7.4.1 HYST (Hysteresis Value)
When not in PWM mode, the PL controls the
battery voltage by simply switching the charge
current on and off. It turns off the charge
current at the relevant set point for the state
(Float, Boost, Equalise, Absorption), and allows
the charge current to turn back on at a slightly
lower voltage. The gap between the two
voltages is called hysteresis.
Example:
With the PL in float mode and slow switching
(non PWM), the charge current will be turned
on until the battery voltage rises to the FLTV
value. Once the FLTV value has been reached,
the charge current will be turned off until the
battery voltage falls to FLTV – HYST (float
voltage minus the hysteresis value) at which time
the charge current will be turned on again until
the battery reaches FLTV and the cycle begins
again.
The larger the hysteresis values, the slower the
rate of switching on and off will be.
Note: If you are switching a mechanical relay for
regulation purposes, you may need to increase
the HYST value so that the relay is not switching
as often.

Rev 6.3.0 12.09.16PL Reference Manual
20
SET/REG/TCMP Selection Summary:
TCMP Function Data Source
0 -5mV°C linear
auto sense
(default)
General Purpose -
use this if in doubt
1 gentle curve
auto sense
BP Solar Block
2 steeper curve
auto sense
Sonnenshein Dry Fit
3 limited range
curve
auto sense
Absolyte battery
4 -5mV°C linear
non auto sense
General Purpose -
use this if in doubt
5 gentle curve
non auto sense
BP Solar Block
6 steeper curve
non auto sense
Sonnenshein Dry Fit
7 limited range
curve
non auto sense
Absolyte battery
8 No temperature
sensor (disable)
(Failsafe: if short
across T- T+ inputs)
Note: Without temp sensor fitted (or if TCMP=8),
the PL will display 0°C.
7
Timers:
The HYST value is also used to start and stop
the timers associated with the different regulator
charging states (Boost, Equalise, and Absorption).
Example:
When the PL changes to the Absorption state,
an internal timer is started to monitor how long
the regulator has been in Absorption. If however
the battery voltage falls lower than ABSV - HYST
this timer is stopped, and starts again when the
battery voltage rises above ABSV - HYST. This
ensures that the regulator holds the system in
the required state for the correct programmed
time and doesn’t continue to the next charging
stage until this time has elapsed.
Note: An exception to this is the Equalise State,
which will terminate after 4 days if unable to
complete the full specified time period.
7.4.2 Charge Current Limit
The PL has a built-in charge current limit. If the
charge current exceeds the CHRG setting, the
PL will reduce the duty cycle to limit the average
charge current.
This allows the PL to protect itself from
overheating due to excessive charge current. The
maximum charge current can also be limited for
small batteries where the full array current might
be too much for the battery. This is useful for
systems, which are marginal in winter, but have too
much charge current for the battery in summer.
It can also be useful where there is an initial
ageing effect in the first few months of the life
of the module. For example, with amorphous
modules the initial current may be more than
the charge current rating of the PL. Making use
of this feature, you can install panels with the full
rating calculated after the initial drop off.
7.4.3 TCMP
(Temperature compensation)
(Default=0, Adjustable in Program 4 only)
A temperature sensor is available which allows
the PL to adjust its regulation voltage settings to
compensate for variations in battery temperature.
The setting TCMP is used to select a
temperature profile, which determines how this
compensation is achieved.
The PL can automatically sense the presence of
a temperature sensor if one of the auto-sense
profiles is selected. If operation at temperatures
near zero is common, it is better to use the non
auto sense profile (TCMP=4-7).
Fig. 7.4.3B shows the temperature compensation
curves for each TCMP setting. Consult your
battery manufacturer for correct compensation
for the battery used.