FIELD TEST PROCEDURE: PPC- D
Test equipment required: Digital Multimeter, jumper wires, flat blade screwdriver.
Conditions: Sunny or bright overcast. System panels installed and operational and capable of producing at least 17 volts (open circuit) for a 12 volt system (34 volts for a 24 volt system, etc.)
WARNING: When connecting and disconnecting wires as instructed in this procedure, be sure that the circuit breakers are in the “OFF” position, otherwise arcing may occur.
WARNING: Most batteries produce hydrogen gas when charging, which is extremely explosive. Avoid making sparks in the vicinity of batteries and provide adequate battery ventilation.
Temperature Sensor Test
1. Unplug temperature sensor. Measure the resistance between the inner and outer conductors of the connector attached to the gray cable. (not the connector on the plate). The resistance should be between 3K ohm and 6K ohm. If sensor is bad, replace it with a good one or leave it disconnected. The PPC-D will not function with a defective sensor installed.
MAKE ALL MEASUREMENTS AND JUMPERS AT THE PPC-D FRONT TERMINALS.
1. Switch Battery, Array, and Load circuit breakers off. Disconnect all wires coming into the Positive (+) side of the controller. Leave factory installed internal wiring intact. Secure each wire away from any possible contact with other wires, metal chassis, enclosures, etc.
2. If there is a jumper between BATTERY (+) and BATTERY SENSE (+), remove it.
Charge relay N.O. contacts
3. Switch Battery circuit breaker on. Switch Array circuit breaker on.
4. Measure the resistance between SOLAR PANEL(+) and BATTERY(+). It should read more than 50K ohm.
Charge mode activation, LVD activation.
5. Switch Battery and Array circuit breakers off.
6. Reconnect the solar panels to the controller. Measure the voltage between SOLAR PANEL (+) and SOLAR PANEL (-) to ensure it is at least 17 volts (for a 12 volt system).
7. Switch the Battery, Array, and Load circuit breakers on. The controller should immediately go into charge mode (“CHARGING” light on) and after a few moments the LVD should activate (“LOAD DISCONNECT” light on). Note: the LVD reset switch is bypassed during this part of the test.
8. Measure the voltage between BATTERY (+) and BATTERY (-). It should be about the same as the panel voltage measured above.
9. Measure the voltage between LOAD (+) and LOAD (-). It should be zero.
Charge mode deactivate, float mode activate, LVD deactivate.
10. Install a jumper between BATTERY (+) and BATTERY SENSE (+). The controller should switch out of charge mode, and after a few moments, the LVD should deactivate.
11. a. For 12 volt and 24 volt systems with float mode only: Measure the voltage between BATTERY (+) and BATTERY (-). It should be between 13.5 volts and 14.2 volts (27.0 and 28.4 for 24 volt systems). Go to step 12.
b. For 36 volt and 48 volt controllers and special controllers without float mode: Install an additional jumper between BATTERY (+) and ARRAY (+).
12. Measure the voltage between LOAD (+) and LOAD (-). It should be the same as the voltage between BATTERY (+) and BATTERY (-).