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REGULATOR
PRODUCT MANUAL
BPR2 NGT
Issue
No.
7.0
AMENDMENTS
AUTH.
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
Product Manual
TABLE OF CONTENTS
1.
INTRODUCTION ............................................................................................... 3
2.
3.
4.
5.
6.
7.
7.1.
7.2.
7.3.
8.
8.1.
9.
10.
11.
TABLE OF FIGURES
FIGURE 1
FIGURE 2
FIGURE 3
TABLE OF TABLES
TABLE 1
TABLE 2
TABLE 3
TABLE 4
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CAUTION
The BPR2-NGT Regulator is supplied as a multi voltage, 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.
1.
INTRODUCTION
The main function of the BPR2-NGT Regulator is to prevent damage to the
battery due to excessive charging or discharging. Additionally, the BPR2-NGT
Regulator has the facility to both control an external generator, and display
system information on the mimic display.
11
15
9
1
3
10
7
8
14
12
13
Figure 1
LED
1-2
3
4
5
6
7
8
9
10
11
12
13
14
15
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LED Functions
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Product Manual
SOLAR REGULATION
The solar array is to be distributed into two circuits, each with a maximum
current rating of 20 Amps in a 12 and 24 volt system, 15 amps for 36 and
48 volt systems.
Use the short circuit current rating of each parallel solar panel or string of panels
to calculate the total current. Each section is controlled by a relay as shown on
the mimic display. 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
LED
STATUS
BOOST MODE
LED 14
OFF
LED 14
FLASHING
LED 14
ON
EQUALISATION
MODE
FLOAT MODE
TEMPERATURE
COMPENSATION
Table 2
3.
Charging Regimes
If the battery voltage drops to 1.90 (2.0)1 Volts/cell {11.4V (12V) in a 12V
system} for 10 minutes, an internal relay closes and remains closed until the
battery voltage rises again to 2.2 (2.2) Volts/cell (13.2V in a 12V system). This
relay can be used to provide a signal for a remote telemetry alarm, or to start
and stop a generator, providing the generator is fitted with an automatic start
control unit.
The second number appearing in brackets () is the value for a battery other than the PVstor battery.
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The regular occurrence of a low voltage alarm is an indication that either too
much power is being used from the battery bank, or that sufficient time is not
being allowed for the battery bank to recharge.
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. Master reset
button sets regular daily start time of the generator.
When using this feature the generator will run until either the voltage rises to
the boost voltage level, or the voltage has been greater than 2.4 (2.3) Volts/Cell
for three hours. Should the generator have been operating for 5 hours
(regardless of the voltage level) the regulator will also shut down the genset.
Refer to Section 7.2 for instructions on how to configure the daily generator start
feature.
The above settings only apply when the daily generator start feature has
been enabled.
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.
4.
Should the battery voltage fall below 1.8 (1.9)1 Volts/cell, {10.8V (11.4) in a 12V
system}, for 10 minutes, the regulator will disconnect all power from the DC
load terminals within the BPR2-NGT Regulator. Power will be reconnected when
the battery voltage rises to 2.2 (2.1) Volts/cell, (13.2V (12.6V) in a 12V system).
This feature allows the batteries to receive a partial recharge before being
returned to service, thus helping prevent battery damage through operating the
system at a low state of battery charge.
NOTE
Inverters should be connected directly to the battery bank (via appropriately
sized over current protection devices eg. HRC Fuses) because of the high
value of D.C. currents involved. These devices should have their own
internal low voltage protection fitted.
The second number (appearing in brackets) is the value for a battery other than the PVstor battery.
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Should the battery voltage rise above 2.65 (2.55) Volts/cell, {15.9V (15.3V) for
12V system}, for 10 minutes, the Red High Voltage Alarm indicator will
illuminate. This alarm signifies that the battery bank is being grossly
overcharged. The high voltage alarm does not disconnect load.
This Alarm will automatically reset once the battery voltage falls to 2.1 (2.1)
Volts/cell, (12.6V in a 12V system).
6.
Parameter
Array Amps
Array A/Hrs
Net Amps
Net Battery
A/Hrs
8
9
Batt Volts
Load Amps
10
Load A/Hrs
15
Minus Sign
Comment
The instantaneous solar current.
Cumulative solar Amp Hours input. The BPR2-NGT Regulator will
record up to 9990 Amp Hrs.
Input Solar Current minus Output Load Current. If positive the
battery is charging.
Net Amp Hrs is the difference between solar input Amp Hours and
load output Amp Hours since the value was last reset. Net Amp
Hours are automatically reset to zero when the battery is equalised.
The instantaneous battery voltage.
The instantaneous load current measured from the load current
shunt.
Cumulative load Amp Hours output. The BPR2-NGT Regulator will
record up to 9990 Amp Hrs.
Indicates if the displayed value is negative.
Table 3
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Display Parameters
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Product Manual
J2
12V
Voltage Select
OFF
1 1
2
3
4
5
6
7
8
ON
1
2
3
4
SW4
Figure 2
7.1.
Sensor
J1
External
Microcontroller
OFF ON
SW3
Internal
12V
24V
36V
48V
Master
Reset Button
Sets Start Time
of Generator
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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 :
SW3 :
SW4 :
1 OFF
2 OFF
3 OFF
4 ON for 48 Volts
7.2.
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level, the battery voltage is above 2.4 (2.3) Volts/Cell for three hours, or for a
maximum of 5 hours.
To disable this feature set SW3 switch number 4 to OFF, and press the main
reset button on the rear of the control PCB.
7.3.
Refer to Figure 3 with each of the terminals J1, J2, J3, and J4, the bridging
piece can be set to short out the centre pin and one of the outer pins.
ALL FOUR JUMPERS MUST BE SET THE SAME WAY.
Figure 3 shows which side is to be bridged for positive earthing, and which side
for negative earthing.
8.
Before installing the regulator, ensure that the ON/OFF switch on the Lower
Half of the BPR2-NGT Regulator, (See Figure 3), is in the OFF position.
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. The top half of the regulator may be set aside to prevent damage during
installation.
The BPR2-NGT Regulator should be wall mounted, in an indoor location,
protected from both rain and direct sunshine. The cable distance between the
solar array, the BPR2-NGT Regulator, and battery should be as short as
possible.
Cables should be sized appropriately to limit the voltage drop between the
terminals of the module and the battery terminals, and also between the battery
terminals and the load.
The regulator is to be secured to the wall via the 4 mounting holes in the lower
half of the regulator enclosure.
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(Optional)
- +- +
J4
J3
J2
J1
Pos Neg
ON/OFF
SWITCH
Figure 3
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, or to the load equipment.
1. Connect the battery to the regulator
2. Connect the array to the regulator
3. Connect the load to the regulator
Disconnection is the reverse order to connection.
Connect the cables to the main terminal block, as described below using Figure
3 as a guide.
For Negative Earth systems, Negative cables connected to terminals marked
COM.
For Positive Earth Systems, Positive cables connected to terminals marked
COM.
a)
Set the ON/OFF switch to OFF, and disconnect the top half of the
regulator by removing the ribbon cable plug from the lower circuit
board.
b)
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c)
d)
e)
f)
g)
h)
i)
9.
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, first releasing the master reset button then
releasing the
button.
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There are 9 sequential test sequences. To move to the next test sequence
again press the button
Self-Test Functions
b)
c)
a)
NOTE
Note fuse location (if required). Fuse rating depends on load size.
b)
c)
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Metering Facility
Display
Type of Enclosure
Ingress protection
Reverse Polarity Protection
Cable Size - Power Cables
Cable Size - Battery sense & Temp
sense
Dimensions
Weight
Cable Gland Facility
12,24,36 or 48 Volts
0-50o C
0 - 95% non condensing
40 Amps DC @ 12 ,24 V 60 Amps DC @ 36,48V
15 Amps DC @ 12 ,24 V 10 Amps DC @ 36,48V
2 Sequential switching N/O relays
Suitable for negative or positive earth- Link Selectable
Internal Sensor Standard (External Optional)
Independent Battery Voltage Sense Terminals
2.50 V/cell (2.4V) returns to float after 30 minutes
2.40 V/cell (2.3V) returns to boost at 2.2 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 :1.80 V/cell (1.9V)
Off : 2.20 V/cell (2.10V)
On :2.65 V/cell (2.55V) Off : 2.10 V/cell (2.1V)
On :1.90 V/cell (2.00V) Off : 2.20 V/cell (2.20V)
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, 270mA @ 24V, 200mA @ 36V, 140mA
@ 48V
External Fusing Required for battery and load circuits.
Internal 2A fuse protection is supplied as standard for the
internal circuit.
1. Battery Voltage
2. Total Array Current
3. Total Array Amp Hrs since reset
4. Load Current
5. Load Amp Hrs since reset
6. Net Battery Current
7. 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.
Polycarbonate
IP40
Included as Standard
up to 16 mm2 Building Wire.
up to 2.5 mm2
H200mm x W230mm x D100mm
1.2kg
4 x PG16 and 2 x PG21 or PG16 knockout provided
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