BPR2-NGT SOLARREGULATOR PRODUCT MANUAL BPR2 – NGT Issue No. 7.0 AMENDMENTS AUTH. General modification in new template Author Date Hamid Naderi 15/07/03 Check Nicole Ghiotto Date 15/07/03 HN CHKD. APPR. NG SP Approved Stephen Poropat Date 15/07/03 ......................... 3 CONFIGURING THE REGULATOR ................................ 12 11................................. 7............................. 5 5.............BPR2-NGT Solar Regulator Product Manual TABLE OF CONTENTS 1........................................................... 7 WIRING INTERFACE DIAGRAM . LOW VOLTAGE DISCONNECT ..... 4 4.................................................................. 10 9...................... 3 CHARGING REGIMES . 3 2........ SCROLLING THE DIGITAL METER DISPLAY ... LOW VOLTAGE ALARM/GENERATOR START .... 8 SELECTING THE EARTHING POLARITY .......... SOLAR REGULATION ........................................... BPR2-NGT REGULATOR SPECIFICATIONS . 8................................................................................................ 10 TABLE OF TABLES TABLE 1 TABLE 2 TABLE 3 TABLE 4 LED FUNCTIONS ...........................1........ ADDITIONAL DISPLAY INFORMATION ............. HIGH BATTERY VOLTAGE ALARM..1..... SETTING THE INTERNAL PCB LINKS.................... 7............................................................................. 7 7...... .................................................................................................. 9 INSTALLING THE BPR2-NGT REGULATOR ...................................................................... CONFIGURING THE BPR2-NGT REGULATOR ........................................ 13 TABLE OF FIGURES FIGURE 1 FIGURE 2 FIGURE 3 BPR2-NGT MIMIC PANEL.................................................................................................................3............. 12 25/06/03 Issue 7 Page 2 of 13 Benbro Electronics ......................................... 11 10.......... INTRODUCTION .......... 6 7....................................................................................................... 4 3................ 4 DISPLAY PARAMETERS ..................... 6 SELF-TEST FUNCTIONS ...................2......................... TESTING THE BPR2-NGT REGULATOR .................. 6 6............................. 9 WIRING TO THE BPR2-NGT REGULATOR ..................................................................................................... 7 SETTING THE TIME OF DAY GENERATOR START FEATURE ......... 8...................... and display system information on the mimic display. Additionally. 11 15 9 1 3 4 2 6 10 7 8 14 12 13 5 Figure 1 LED 1-2 3 4 5 6 7 8 9 10 11 12 13 14 15 BPR2-NGT REGULATOR LED FUNCTIONS Colour Function Manual Section Green Array 1-2 Status 2 Green Array Amps 6 Green Array Amp Hours 6 Green Temperature 6 Green Net Battery Amps 6 Green Net Battery Amp Hours 6 Green Battery Voltage 6 Green Load Amps 6 Green Load Amp Hours 6 Red Load Disconnect 4 Red High Volt Alarm 5 Yellow Low Volt Alarm or 3 Genset Control Green Regulation Status 2 Red Minus Sign 6 Table 1 25/06/03 Issue 7 BPR2-NGT Mimic Panel LED Functions Page 3 of 13 Benbro Electronics .BPR2-NGT Solar Regulator Product Manual CAUTION The BPR2-NGT Regulator is supplied as a multi voltage. 1. INTRODUCTION The main function of the BPR2-NGT Regulator is to prevent damage to the battery due to excessive charging or discharging. the BPR2-NGT Regulator has the facility to both control an external generator. negative earth unit with an internal temperature sensor. Before installing the BPR2NGT Regulator the internal links and Dip-switches MUST be configured as detailed in this manual. 15 amps for 36 and 48 volt systems. 25/06/03 Issue 7 Page 4 of 13 Benbro Electronics .) If the battery voltage drops to 1.2V in a 12V system). LED 14 OFF LED 14 FLASHING LED 14 ON EQUALISATION MODE FLOAT MODE TEMPERATURE COMPENSATION Table 2 3. Product Manual SOLAR REGULATION The solar array is to be distributed into two circuits. or to start and stop a generator.2 (2.1) Volts per cell (13. an internal relay closes and remains closed until the battery voltage rises again to 2. Following equalisation the battery voltage is allowed to fall to 2. Display reads 111 if temperature sensor is faulty or is not connected Charging Regimes LOW VOLTAGE ALARM/GENERATOR START (Indicated by Yellow LED 13 on the mimic display.8V) in a 12 V system) and is maintained at this level. Use the short circuit current rating of each parallel solar panel or string of panels to calculate the total current. to ensure all cells are 100% charged and equalised. If the battery voltage drops below 2.4V (12V) in a 12V system} for 10 minutes. Green LEDs 1 and 2 are illuminated if the relay is closed and therefore that portion of the solar array is charging the solar battery. REGULATION MODE REGULATION MODE TERMINOLOGY LED STATUS BOOST MODE Charging will allow the battery voltage to rise to the boost voltage level of 2. 90mV in a 36V system and 120mV in a 48V system.0)1 Volts/cell {11. in a 12 volt system. Battery voltages are temperature compensated by – 30 mV/°C rise above 20°C.BPR2-NGT Solar Regulator 2. 1 The second number appearing in brackets () is the value for a battery other than the PVstor battery.4V)1 in a 12 V system) @ 20º C.3) Volts per cell (14. When the Boost Voltage has been reached the BPR2-NGT Regulator maintains the boost voltage for 30 minutes.90 (2.6V) in a 12 V system) the BPR2-NGT Regulator will revert to boost mode.4) Volts per cell (ie 15V (14. each with a maximum current rating of 20 Amps in a 12 and 24 volt system.4V (13. 60mV in a 24V systems. Each section is controlled by a relay as shown on the mimic display.2 (2.5 (2. providing the generator is fitted with an automatic start control unit.2V (12.4 (2. This relay can be used to provide a signal for a remote telemetry alarm.2) Volts/cell (13. 6V) in a 12V system).8 (1. (13.8V (11. Refer to Section 7. 4. If a generator is connected to the system and the generator daily start feature is not set then the generator will only operate on the standard low volt alarm levels. HRC Fuses) because of the high value of D. Master reset button sets regular daily start time of the generator. thus helping prevent battery damage through operating the system at a low state of battery charge. LOW VOLTAGE DISCONNECT (Indicated by Red LED 11 on the mimic display. This feature allows the batteries to receive a partial recharge before being returned to service. the regulator will disconnect all power from the DC load terminals within the BPR2-NGT Regulator.2 for instructions on how to configure the daily generator start feature.1) Volts/cell. NOTE Inverters should be connected directly to the battery bank (via appropriately sized over current protection devices eg.4 (2. The above settings only apply when the daily generator start feature has been enabled. or the voltage has been greater than 2.4) in a 12V system}.2 (2. Power will be reconnected when the battery voltage rises to 2.C.) Should the battery voltage fall below 1. These devices should have their own internal low voltage protection fitted. 1 The second number (appearing in brackets) is the value for a battery other than the PVstor battery. 25/06/03 Issue 7 Page 5 of 13 Benbro Electronics . Should the generator have been operating for 5 hours (regardless of the voltage level) the regulator will also shut down the genset. or that sufficient time is not being allowed for the battery bank to recharge. {10.3) Volts/Cell for three hours. currents involved. When using this feature the generator will run until either the voltage rises to the boost voltage level. for 10 minutes.2V (12.BPR2-NGT Solar Regulator Product Manual The regular occurrence of a low voltage alarm is an indication that either too much power is being used from the battery bank. If a generator is included in the system the ‘Time of Day Generator Start Feature’. using the Internal 24 Hour Clock. may be used to start the generator and provide a regular charge to the batteries on a daily basis.9)1 Volts/cell. If positive the battery is charging. The instantaneous battery voltage.1 (2.9V (15. Cumulative solar Amp Hours input.7. Cumulative load Amp Hours output. for 10 minutes. This Alarm will automatically reset once the battery voltage falls to 2.) Should the battery voltage rise above 2. {15. or 10 are flashing it is necessary to multiply the meter reading being displayed by 10 to obtain the correct value. This alarm signifies that the battery bank is being grossly overcharged. If LEDs 4. (12. SCROLLING THE DIGITAL METER DISPLAY The display is activated by pressing the button on the mimic display panel. Indicates if the displayed value is negative. If the button is not pressed for 5 minutes the display will turn off to conserve power.3V) for 12V system}. A green LED on the mimic display indicates which parameter is currently displayed. The instantaneous load current measured from the load current shunt.1) Volts/cell. Input Solar Current minus Output Load Current. Net Amp Hours are automatically reset to zero when the battery is equalised. Product Manual HIGH BATTERY VOLTAGE ALARM (Indicated by Red LED 12 on the mimic display.65 (2. Table 3 25/06/03 Issue 7 Display Parameters Page 6 of 13 Benbro Electronics . The high voltage alarm does not disconnect load. 6. Ampere hour values are reset by pressing and holding the mimic button on the front panel continuously for 30 seconds.55) Volts/cell. The BPR2-NGT Regulator will record up to 9990 Amp Hrs. The BPR2-NGT Regulator will record up to 9990 Amp Hrs.BPR2-NGT Solar Regulator 5. the Red High Voltage Alarm indicator will illuminate. Net Amp Hrs is the difference between solar input Amp Hours and load output Amp Hours since the value was last reset. Pressing the button again will scroll the display to the next parameter. LED 3 4 Parameter Array Amps Array A/Hrs 6 Net Amps 7 Net Battery A/Hrs 8 9 Batt Volts Load Amps 10 Load A/Hrs 15 Minus Sign Comment The instantaneous solar current.6V in a 12V system). Product Manual CONFIGURING THE BPR2-NGT REGULATOR >12V J2 12V Voltage Select Rear of Control PCB Factory Setting are shown OFF 1 1 2 3 4 5 6 7 8 ON 12V 24V 36V 48V System ON ON OFF OFF Voltage ON OFF ON OFF Battery OFF = PVstor. ON = Standard Temp Genset Timer ON=Daily Start 2 Stage/4 Stage Load Shunt OFF=1mV/A.1. (The BPR2-NGT Regulator as supplied. ON=0.5mV/A Not Used Not Used 1 2 3 4 SW4 Figure 2 7. Sensor J1 External Microcontroller OFF ON SW3 Internal 12V 24V 36V 48V Master Reset Button Sets Start Time of Generator Configuring the Regulator Setting the Internal PCB Links.BPR2-NGT Solar Regulator 7.) The following are the factory settings for the BPR2-NGT regulator: 48V operation PVstor Batteries Daily generator start function disabled Load shunt setting 1mV/Amp (ie 50mV=50Amps) Internal temperature sensor 2-Stage operation Negative Earth Polarity 25/06/03 Issue 7 Page 7 of 13 Benbro Electronics . To set the start time it is necessary to press the main reset button on the rear of the control PCB at the actual time of day the generator start is required. The BPR2-NGT Regulator will then attempt to start the generator every day at this time. Jumper J1 : In up position (ie Internal temperature sensor) Jumper J2 : In up position (ie >12V) SW3 : SW4 : 1 ON for 24 Volts 2 OFF for 24 Volts 3 OFF for PVStor Battery 4 ON for Genset Daily start 5 OFF for 2 array stages 6 ON for 50mV/100Amp 1 OFF for 24 Volts 2 ON for 24 Volts 3 OFF 4 OFF Example 2 48 Volt system Standard Lead Acid Batteries External Temperature sensor 50mV/50Amp Load Shunt Jumper J1: Jumper J2 : In down position (ie External temperature sensor) In up position (ie >12V) SW3 : 1 OFF for 48 Volt 2 OFF for 48 Volt 3 ON for Standard Lead Acid Batteries 4 OFF for Genset Timer On 5 OFF for 2 array stages 6 OFF Load shunt Off SW4 : 1 OFF 2 OFF 3 OFF 4 ON for 48 Volts 7. The generator will run until either the batteries reach the boost voltage 25/06/03 Issue 7 Page 8 of 13 Benbro Electronics .2.BPR2-NGT Solar Regulator Product Manual The following examples demonstrate how the regulator can be configured. Example 1 24 Volt system PVstor Batteries Internal temperature sensor Generator daily start 50mV/100Amp Load shunt. Setting the Time of Day Generator Start Feature To enable this feature set SW3 switch number 4 to the ON position. J3. protected from both rain and direct sunshine.3) Volts/Cell for three hours. The top half of the regulator may be set aside to prevent damage during installation. Figure 3 shows which side is to be bridged for positive earthing. 7. The regulator is to be secured to the wall via the 4 mounting holes in the lower half of the regulator enclosure. The BPR2-NGT Regulator should be wall mounted. and battery should be as short as possible. is in the OFF position.3. or for a maximum of 5 hours. the bridging piece can be set to short out the centre pin and one of the outer pins. and J4.BPR2-NGT Solar Regulator Product Manual level. ALL FOUR JUMPERS MUST BE SET THE SAME WAY. Selecting The Earthing Polarity Refer to Figure 3 with each of the terminals J1. Cables should be sized appropriately to limit the voltage drop between the terminals of the module and the battery terminals. 25/06/03 Issue 7 Page 9 of 13 Benbro Electronics . For ease of installation the Top half of the BPR2-NGT Regulator may be removed by unplugging the ribbon cable from the socket on the lower circuit board. and also between the battery terminals and the load. the battery voltage is above 2. J2. ensure that the ON/OFF switch on the Lower Half of the BPR2-NGT Regulator. in an indoor location.4 (2. To disable this feature set SW3 switch number 4 to OFF. 8. the BPR2-NGT Regulator. (See Figure 3). INSTALLING THE BPR2-NGT REGULATOR Before installing the regulator. and press the main reset button on the rear of the control PCB. The cable distance between the solar array. and which side for negative earthing. Positive cables connected to terminals marked COM. a) Set the ON/OFF switch to OFF. Connect the battery to the regulator 2. Negative cables connected to terminals marked COM. Connect the cables to the main terminal block.1.BPR2-NGT Solar Regulator 8. Product Manual Wiring to the BPR2-NGT Regulator Low Voltage Alarm Temp Sense (+) Temp Sense (-) Battery Sense (+) Battery Sense (-) High Voltage Alarm (Optional) Load Cut Alarm . b) Connect the battery power cables to the regulator terminal block marked BATT and COM. and disconnect the top half of the regulator by removing the ribbon cable plug from the lower circuit board. 1.+ J4 J3 J2 J1 Pos Neg ON/OFF SWITCH Com A2 Com A1 Com Batt Com Load Figure 3 Wiring Interface Diagram NOTE When connecting or disconnecting component parts of a solar system the following sequence of works should be followed in order to prevent damages to the system components. as described below using Figure 3 as a guide. 25/06/03 Issue 7 Page 10 of 13 Benbro Electronics . Connect the load to the regulator Disconnection is the reverse order to connection. For Negative Earth systems. For Positive Earth Systems. Connect the array to the regulator 3. or to the load equipment.+. J2 when connecting an external load shunt and remove links J3. and SH2+ and SH2-. d) If an External Temperature Sensor is being used: Set Jumper J1 on the top circuit board of the regulator to External Temp Sensor (refer to Figure 2) Connect the temperature sense cables to the small terminal block marked TS+ and TS-. f) Connect the array wires to the regulator terminal block marked A1 and COM. (refer to Figure 3). Shunts to the terminals marked SH1+. The sensor should be mounted on the side of the battery. e) Connect the battery power cables. and J4 when connecting an external solar shunt from the lower printed circuit board. 25/06/03 Issue 7 Page 11 of 13 Benbro Electronics . to the battery bank. The ON/OFF switch can now be turned ON. h) Should EXTERNAL shunts or generator start be required. A2 and COM.BPR2-NGT Solar Regulator Product Manual c) Connect the battery sense cables to the small terminal block marked BS+ and BS-. NOTE: Current polarity of the external temp sensor must be observed. TESTING THE BPR2-NGT REGULATOR The BPR2-NGT Regulator has built in test software that is activated by pressing the master reset button on the rear of the control PCB whilst also holding down the button on the mimic display. including the battery sense wires. i) Generator to terminals marked LV. g) Connect the load cables to the regulator terminal block marked LOAD and COM. Reconnect the top half of the BPR2-NGT Regulator by reconnecting the ribbon cable plug. first releasing the master reset button then releasing the button. Attach the sensor to one of the cells in the battery bank using a sensor fixing kit. It is necessary to REMOVE links J1. and SH1-. and in very close contact with the battery. A3 and COM and A4 and COM. 9. connect the cables to the small terminal block on the lower printed circuit board. The software revision number will be displayed on turn on. below the permanent electrolyte level. 2 and 3 of SW3 (0 = off. 25/06/03 Issue 7 Page 12 of 13 Benbro Electronics . Fuse rating depends on load size. 9 = on) displayed from right to left 9 Cycles through the Relays and indication LEDs. 5 and 6 of SW3 (0 = off. a) NOTE Note fuse location (if required). Self-Test Functions ADDITIONAL DISPLAY INFORMATION a) Faulty Temperature Sensor: Display will read 111. b) Battery Sense connections are required in ALL installations c) BPR2-NGT Regulator Terminal rail will accept 16mm² building wire. To return to normal operation press the master reset button only. 9 = on) displayed from right to left 8 Displays 0 or 9 for state of switch setting 4. Table 4 10. b) Faulty Battery Sense Connection: Display will read 222. Larger cables require an external junction box. c) Software Version Number: Display will read version number when reset button is pressed. To move to the next test sequence again press the button on the mimic display.BPR2-NGT Solar Regulator Product Manual There are 9 sequential test sequences. The order of test sequences is as follows: BUTTON PRESS FUNCTION 1 Cycles through display LEDs 2 Cycles through display LEDs 3 Displays the Battery Voltage 4 Displays load current if a current shunt is installed 5 Displays array current if current shunt is installed 6 Displays regulator calculation temperature in ºC 7 Displays 0 or 9 for state of switch setting 1. 10 V/cell (2.1V) 30 Minutes (time to return to float mode from boost mode) ON Float Mode Flashing Equalisation Mode OFF Boost Mode On :1.5 mm2 H200mm x W230mm x D100mm 1. Product Manual BPR2-NGT REGULATOR SPECIFICATIONS Nominal System Voltage (user selectable) Ambient Temperature Humidity Max Array Current Max Load Current Form of Regulation Earthing Battery Temperature Sensor Voltage Monitoring Boost Charge Regulation Point @ 20C Float Charge Regulation Point @ 20 C Equalisation Period Regulation Status Indication Green LED Load Disconnect Set points High Voltage Alarm Set points Low Voltage Alarm Set points Load Disconnect Alarm (delayed) High Voltage Alarm (delayed) Low Voltage Alarm (delayed) Quiescent Current Consumption Overload / Short Circuit Protection Metering Facility Display Type of Enclosure Ingress protection Reverse Polarity Protection Cable Size .2kg 4 x PG16 and 2 x PG21 or PG16 knockout provided Note: Values in brackets () above are for non-PVStor battery settings 25/06/03 Issue 7 Page 13 of 13 Benbro Electronics .3V) returns to boost at 2.20 V/cell (2.24 V 60 Amps DC @ 36.36 or 48 Volts 0-50o C 0 .Battery sense & Temp sense Dimensions Weight Cable Gland Facility 12. 140mA @ 48V External Fusing Required for battery and load circuits. Load Amp Hrs since reset 6.20V) Red LED and N/O clean contact relay output Red LED and N/O clean contact relay output Yellow LED and N/O clean contact relay output 400mA @ 12V. Load Current 5. Internal 2A fuse protection is supplied as standard for the internal circuit. 270mA @ 24V.20 V/cell (2.2 V/cell (2.24.65 V/cell (2.95% non condensing 40 Amps DC @ 12 .55V) Off : 2.48V 15 Amps DC @ 12 .00V) Off : 2.1V) On :1. up to 2.48V 2 Sequential switching N/O relays Suitable for negative or positive earth. Polycarbonate IP40 Included as Standard up to 16 mm2 Building Wire. Total Array Current 3.Power Cables Cable Size .50 V/cell (2. Battery Voltage 2.BPR2-NGT Solar Regulator 11.9V) Off : 2.40 V/cell (2.10V) On :2. Net Battery Current 7.90 V/cell (2.Link Selectable Internal Sensor Standard (External Optional) Independent Battery Voltage Sense Terminals 2. 1. Net Battery Amp Hrs since last equalisation 3 “7 Segment” LED displays 8 Discrete LEDs and mimic display to indicate parameter displayed on “7 segment” displays. 200mA @ 36V.24 V 10 Amps DC @ 36.80 V/cell (1.4V) returns to float after 30 minutes 2. Total Array Amp Hrs since reset 4.