PulseTech PT20 User manual

INSTALLATION MANUAL
For Model PT20 Charge Controller
PT20 Charge Controller
Model: PT20
Part #: 746X920
Input: DC12V or DC24V solar panel array (Max 50Voc)
Output: DC 12V 20A
DC 24V 20A
User Manual
What comes in the box:
1 each: PT20 Charge Controller
1 each: User Manual
1 each: Temperature Sensor (2.9m in length)
1 each: Fused Battery Harness (3m in length)
1 each: Solar Input Adapter (allows bare wire
connection to solar input)
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THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR INSTALLATION AND
MAINTENANCE OF THE PT20 CHARGE CONTROLLER
Contents
1) IMPORTANT SAFETY INSTRUCTIONS - PLEASE READ 3
2) Overview 4
Intro 4
PulseTech 4
3) Features 4
4) Wiring and Installation 5
Important Installation Notes - Please Read 5
Device Connections 6
Button 6
Installation Guide 12-Volt and 24-Volt 6
12-Volt Installation Specifics 7
24-Volt Installation Specifics 7
5) PulseTech Functionality 8
6) Charging Profiles 9
7) LED Operation 10
8) Troubleshooting 11
9) Specifications 12
10) Contact Us 13
Figure 1: PT20 Side View Figure 2: PT20 Top View
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• WARNING: WHEN A GROUND FAULT IS INDICATED, BATTERY TERMINALS
AND CONNECTED CIRCUITS MAY BE UNGROUNDED AND HAZARDOUS.
• LEAD-ACID, AGM AND LITHIUM BATTERIES CAN BE DANGEROUS.
ENSURE NO SPARKS OR FLAMES ARE PRESENT WHEN WORKING NEAR
BATTERIES.
• NEVER SHORT CIRCUIT THE BATTERY.
• SOLAR PANELS WILL GENERATE ENERGY WHEN THEY ARE EXPOSED
TO LIGHT EVEN WHEN DISCONNECTED. ANY CONTACT WITH WIRES
CAN CAUSE INJURY.
• NEVER USE THIS DEVICE WITH A LITHIUM BATTERY THAT DOES NOT
HAVE A BATTERY MANAGEMENT SYSTEM (BMS).
A BMS IS CRITICAL FOR LITHIUM BATTERY SAFETY.
• Eye protection should always be used when working near batteries.
• Accidental shorting of the wiring during installation can result in sparks
causing personal injury or a fire hazard. PulseTech recommends covering the
solar panels to block all light from reaching the surface.
• Use the provided 12-AWG, 105°C wire harnesses for the solar and battery
connections.
• Always install a battery fuse (25-amp recommended) between the battery and
the solar controller. (See Wiring and Installation section for more details on
fusing.)
• Be very careful not to connect the wires to the solar panel or battery in
reverse.
• Do not disassemble the controller. Please contact PulseTech Customer
Service if you have any problems with your device at
800-580-7554 or [email protected].
• Device has overcurrent protection up to 22-amps on both the solar and
battery terminals.
• PulseTech recommends not exceeding 20-amps of short circuit current (Isc)
for your solar input.
• Audible buzzing noise during charging is normal, particularly during
absorption and float modes. The noise is due to the PT20 charging
functionality of the device and not an indication of a device failure.
WARNING
WARNING: This product can expose you to chemicals including
arsenic, which is known to the State of California to cause cancer.
For more information, go to www.P65Warnings.ca.gov.
1) IMPORTANT SAFETY INSTRUCTIONS - PLEASE READ
!
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2) Overview
Intro
The PulseTech PT20 solar charge controller monitors, regulates and
protects the attached solar components. The PT20 automatically controls
the solar charging power for optimal battery health. Equipped with
advanced, high efficiency, pulse width modulated (PWM) technology and
temperature compensation, batteries safely charge to 100% every time.
PulseTech
Patented PulseTech pulsing technology increases the life of lead-acid
batteries. PulseTech works by desulfating, or removing, and hindering the
natural sulfation (corrosion) that occurs in all lead-acid/ AGM batteries
that eventually leads to a dead battery. PulseTech patented technology
has been proven to increase the life of lead-acid/AGM batteries by
three times their normal life. This technology is built into the PT20 and
is automatically enabled to be turned on for any lead-acid/AGM battery
charging profile and is active during charging only.
3) Features
1. 20-amp Pulse Width Modulation (PWM) Solar Charge Controller
2. Charge 12-volt and 24-volt battery systems using 12-volt or 24-volt solar
panels
3. Preprogrammed battery charging profiles selectable using built-in button
a. AGM, WET and GEL lead-acid type batteries
b. Lithium battery profile to be used for Lithium Iron Phosphate and
Lithium Ion batteries
c. Press and hold button to change between profiles
4. PulseTech pulsating technology to increase the life of all lead-acid
battery types (See PulseTech Functionality Section for more details.)
5. Recharge
a. 20-amps of pure regulated sunlight will recharge your batteries
faster and safer than a generator or alternator
b. 12 and 24-volt auto-switching
c. Advanced pre-programed multi-staged charging algorithms for
AGM, Gel, Wet, and Lithium battery types
6. Restore
a. Patented Pulse Technology removes and inhibits growth of
battery killing sulfate deposits to extend the performance and life
of your hard working batteries
b. Included temperature sensor for optimal charging and safe
temperature compensation
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4) Wiring and Installation
IMPORTANT INSTALLATION NOTES - PLEASE READ
1. Use the provided 12-AWG, 105°C wire harnesses for the solar and
battery connections.
2. Ensure that your solar input has a maximum short circuit current (Isc)
of no more than 20-amps.
3. Always use a 25-amp fuse between the battery and the charge
controller.
4. The maximum overcurrent protection of the PT20 is 22-amps.
5. It is important to use the external temperature sensor to ensure
proper battery charging for all lead-acid/AGM battery types. Please
tape the ring terminal end to your battery or connect it to the positive
battery post. Do not use the temperature sensor for Lithium batteries.
6. Immediately after connecting the battery to the charge controller, use
the button to change the battery profile. Do this before connecting
your solar panels to the device.
7. Put the device in a well ventilated area.
Battery harness Solar Input
ATP Plug w/6"12-AWG
with butt splices
7. Maintain
a. The PT20 Solar Charge Controller is always working,
even when your batteries are not
b. Protects your batteries from overvoltage, overcurrent,
reverse polarity, and reverse current damage
c. Rugged “all-weather” design will maintain your battery
investment in the harshest conditions
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Device Connections
The PT20 has three separate connectors that come out of the housing.
The solar and battery connectors are both 25A rated ATP connectors.
When used with the solar battery harness, the polarity will be indicated
with red as positive and black as negative for both the battery and the
solar sides. The third, smaller connector is for the temperature sensor.
If you remove the ATP connectors, polarity is indicated with Red as
positive and Black as negative for both solar and battery connections.
Harness info:
Battery: 3 meter, 12-AWG wire from battery to charge controller - 25A Fuse
Solar: ATP Plug w/6"12-AWG with butt splices
Ratings:
12V System: 15V-28V
12V Maximum Nominal Panel Wattage: 400W
24V System: 30V-50V
24V Maximum Nominal Panel Wattage: 800W
Array can be safely left floating. No external protection devices required.
However, PulseTech recommends using a fuse on the positive output of
each solar panel to protect your solar panel. All Zamp Solar Panels have
a fuse built into the harness.
Button
Use the button that says “Press & Hold” to change the active battery
profile. Press and hold the button for 2 seconds until the battery type
LEDs begin cycling. When the LED next to the battery type you would
like illuminates/lights, release the button. Ensure that the battery type
you want has the LED next to it illuminated.
Installation Guide 12-Volt and 24-Volt
Charge Controller to Battery Wiring
Connect the charge controller to the battery using the supplied 3
meter, 12-AWG, 105ºC copper wire. When connecting the charge
controller to the battery, ensure there is a 25-amp fuse on the
positive side of the charge controller to the battery connection.
Battery Fusing
Examples of fuses to use are a terminal fuse block, manual resetting
breaker or an ANL type fuse. A 25-amp fuse is recommended for all
installations.
Automatic resetting breakers are NOT recommended.
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Temperature Sensor
The PT20 comes with a 2.9m (9.5 ft.) temperature sensor with a ring
terminal on one end and two leads on the other end. If using a lead-
acid/AGM battery, connect the temperature sensor to the charge
controller by pressing the two connectors together. Once connected,
give each lead a light tug to ensure that they are properly fitted. Then
tape the ring terminal side of the temperature sensor to the side or
the top of your battery. This is recommended over connecting it to
one of the battery terminals because it will give a better gauge of
the actual temperature of your battery. It is important to use this as
described to enable the charge controller to accurately charge your
battery bank over all temperature ranges. (See the Charging Profiles
section for information on temperature behavior during charging.)
12-Volt Installation Specifics
24-Volt Installation Specifics
Table 1: 12-Volt Installation Quick Information
Maximum Nominal Panel Wattage 400W (<= 20A lsc)
Battery to Charge Controller Wire Size 12-AWG
Battery to Charge Controller Fuse Size 25A
Battery to Charge Controller Wire Length (MAX) 9.84 ft. (3m) *included
Solar Panel to Charge Controller Wire Size 12-AWG
Solar Panel to Charge Controller Wire Length (MAX) 15 ft.
Solar Panel Configuration Parallel (12V)
Temperature Sensor (Use for Lead-Acid/AGM only) Tape to top or side of the battery
Table 2: 24-Volt Installation Quick Information
Maximum Nominal Panel Wattage 800W (<= 20A lsc)
Battery to Charge Controller Wire Size 12-AWG
Battery to Charge Controller Fuse Size 25A
Battery to Charge Controller Wire Length (MAX) 9.84 ft. (3m) *included
Solar Panel to Charge Controller Wire Size 12-AWG
Solar Panel to Charge Controller Wire Length (MAX) 15 ft.
Solar Panel Configuration 2 - 12V panels in Series = 24V
or 24V panel
Temperature Sensor (Use for Lead-Acid/AGM only) Tape to top or side of the battery
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5) PulseTech Functionality
The PT20 controller contains a proprietary, patented PulseTech Pulsing
circuit that has been scientifically proven to extend the life of all types of
lead acid batteries. This is achieved using PulseTech’s patented pulsing
technology that breaks up the lead sulfates that build up on the plates
inside the battery whenever the battery is discharging.
Sulfates negatively impact battery performance by:
• Reducing the battery’s ability to discharge power
• Reducing the battery’s ability to recharge
• Shortening battery life
Pulse Technology is delivered to the battery through a circuit which
is independent of the charging circuit. This patented, high-frequency
pulse waveform is of a specific amplitude and frequency that is
precisely controlled by microprocessors. It rises rapidly in less than one
microsecond to its maximum amplitude and gradually returns to zero.
There is no abrupt stop and no battery drain. This waveform occurs
25,000 times a second and has been proven to remove sulfation from
the battery plates and return the lead sulfate back to the electrolyte
solution.
For more detailed information, visit the website here:
https://www.pulsetech.net/our-technology/pulse-technology.html
The pulse circuit is applied on top of the charging waveform. Thus, the
pulse circuit requires the device to be charging in order to function.
The PulseTech Pulsing is automatically enabled on all Lead-Acid/AGM
battery profiles and can't be turned off in the settings. For all Lithium
battery profiles, the PulseTech Pulsing has been disabled to prevent
battery damage.
Figure 3: PulseTech Pulse Technology Waveform
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6) Charging Profiles
The PT20 contains 4 pre-programmed, multi-stage battery profiles that
have been customized to each specific battery type. There are profiles
for AGM, Gel, Conventional Lead-Acid (WET) and Lithium (Lithium Ion
& LiFePo4) Batteries. See Table 3 below for detailed descriptions of the
different charging stages.
(1) BMS systems should not ever allow the battery to discharge below 10V.
(2) This range is for the board temperature. If no battery temperature sensor is connected, the device can only read the
board temperature. Ensure that the device does not operate above the ambient temperature maximum rating given in
Table 4.
Table 3: Default Charging Profile Voltage and Current Descriptions
Default Charging Profile Voltage and Current Descriptions
This table shows the 12V system voltage, double the voltage given for a 24V system.
AGM
(Default)
Gel Wet/Flooded Lithium (LiFePo4/LiIon
Soft Charge
Voltage
8V - 10V BMS Lower Cutoff - 10V (1)
Soft Charging
Current
4A (2A for 24V)
Bulk Charge
Voltage
10V-Absorption Voltage
Bulk Charge
Current
Max current available up to 20A
Absorption
Charge Voltage
14.6V 14.1V 14.7V 14.4V
Absorption to
Float Condition
1. Charging current drops below 1A (or)
2. Charger has been in absorption mode for 4 hours
Float Charge
Voltage
13.6V 13.3V 13.4V No Float
Default Restart
Charge Voltage
13.3V 13.0V 13.1V 13.3V
Pulsing
Waveform
Applied
Apply pulse in define waveform when solar panel
voltage is available battery is charging
Pulsing Circuitry not allowed
Min ~ Max
Charging
Temperature
with Sensor
-4ºF ~ 113ºF
-20ºC ~ 45ºC
-4ºF ~ 113ºF
-20ºC ~ 45ºC
-4ºF ~ 124.7ºF
-20ºC ~ 51.5ºC
The charger relies on the
battery’s internal BMS to cut
off charging due to high or low
temperatures.
Max Charging
Temperature
without Sensor
212ºF (2)
100ºC (2)
Temperature
Compensation
-30mV/ºC for 12V Lithium batteries:
-60mV/ºC for 24V No temperature compensation
Voltage Output
Accuracy
+/- 0.1V
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7) LED Operation
Solar Status LED
This LED gives the current status of the connected solar array.
Green = Solar is present and >15V
Off = Solar is <15V
Battery Status LED
This LED gives the current charging state of the controller.
Solid Green = Float/Fully charged
Fast Blinking Green (six times per second) = Absorption
Solid Orange = Bulk Charging
Solid Red = Soft Charging
Blinking Red = Battery Error
Off = No Battery Connected
Pulse LED
This LED gives the current status of the on-board PulseTech Pulsing Technology.
Blinking Red = PulseTech Pulsing Technology is active and pulsing
Off = Pulsing is off
12 Volt LED
This LED is lit if the device detects a 12V battery.
Solid Green = System voltage is 12V
Off = System voltage is 24V
24 Volt LED
This LED is lit if the device detects a 24V battery.
Solid Green = System voltage is 24V
Off = System voltage is 12V
Battery Type LEDs
These LEDs indicate the active battery type. Only one will be on at a time. Use
the button to change between battery types. (See the Button section for more
information – see Page 6.)
Solid Green = Battery Type listed is set as the active profile
Off = Another battery type is set as the active profile
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8) Troubleshooting
Battery Removal Procedure
If you are going to remove your battery during a period of very low Solar
Input (i.e. nighttime, inside a shop with no lighting, etc.), you must also
remove the solar panel input. If you remove the battery input and leave
a weak solar input, the controller will consider its power source too
variable and enter a shutdown state. This can be remedied by removing
the solar input and re-attaching the battery input.
If you are removing your battery with plenty of solar input (i.e. any
condition where the sun is present), you may disconnect your battery
freely without removing the solar input. It is important that you re-
connect the battery before the sun goes down to avoid exposing the
controller to very weak solar input.
Controller “blinking orange and green”
If you are looking at the front face of your PT20 Charge Controller during
dusk or dawn, you may observe that the battery status light is switching
quickly between green and orange. This may look like an error, but it
is not. The two colors of the LED represent 2 charging states that are
being encountered quickly due to the behavior of the charger. Orange
occurs when the device enters Bulk mode in an attempt to charge using
the available sun. Since the sun is weak during dusk and dawn, there
is not sufficient current to cause the device to continue charging and
thus it enters an idle state which is represented by a green color on the
battery status LED. Since the solar controller always wants to be in a
charging mode, the device will then reattempt charging and the LED will
turn orange again and begin the cycle all over. This orange-green LED
blinking is normal controller behavior and nothing to worry about.
Controller is “buzzing” and making noise
You may notice that the PT20 occasionally makes a buzzing noise
during charging. This is normal. This buzzing will only occur during
Float/Absorption modes and indicates that the charger is limiting the
current to your battery as it proceeds through its normal three stage
charging process.
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9) Specification
Table 4: Specifications for PT20
Specification Details
Battery Voltage 12/24V (Automatically Detected)
12V System: 8V ~ 16V
24V System: 16V and up
Maximum Voltage on Battery
Terminals
40V
Rated Charge Current 20A
Minimum Solar Input Voltage 12V Battery: 15V
24V Battery: 30V
Maximum Open Circuit Solar
Panel Voltage
50V
(recommended <28V for 12V)
Maximum PV Short Circuit
Current (1)
22A
Maximum Nominal Panel
Wattage
12V: 400W
24V: 800W
Self-Discharge <60mA
Protection Reverse polarity at solar input
Reverse polarity at battery input
Protection against reverse current from battery to solar
Over temperature protection
Input Terminals Male 25A Rated ATP connector at the end of 10cm 12AWG wire
for solar input
Female 25A Rated ATP connector at the end of 10cm 12AWG
wire for Battery input
Small Female JWPF for External Temperature Sensor Input at the
end of a 10cm 26AWG wire
Humidity (non-condensing) Max 98%
Battery Temperature Sensor
(Use for Lead-Acid/AGM
batteries only)
Included with device
Tape to Battery for accurate temperature compensation
For lead-acid/AGM battery types during charging
Min~Max Operating Ambient
Temperature Range
-31ºF ~ 149ºF
-35ºC to +65ºC
Protection Category Tested to IP66 standards
Weight 1.43 lb / 0.65 kg (includes temperature sensor)
Dimensions (h x w x d) 3.62"x 4.53"x 1.52"(92mm x 115mm x 38.5mm)
Standards ETL + ETLc: UL 1741; CSA C22.2 No. 107-1
FCC Part 15B (Class A)
CE/EMC: EN61000-6-2 and EN61000-6-4
CE/LVD: EN62109-1
CB: IEC 62109-1
Australia (Safety EMC RCM)
(1) Overcurrent protection set at 22-amps for the PT20. PV short circuit current above this value may damage the device.
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Figure 4: PT20 Mounting Diagram
10) Contact Us
PulseTech Products Corporation
1100 S. Kimball Ave.
Southlake, TX 76092-9009
[email protected]
www.pulsetech.net
Toll Free: 800-580-7554
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