Model PV7 /D & PV14
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Model PV7 /D & PV14
1217 State St., Charlevoix, MI 49720 Ph: (231) 547-9430 Fax: (231) 547-5522
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http://www.flexcharge.com
Page1
PV7-PV14 manual.doc
Model PV7 /D & PV14
Owners Manual
PV7
PV7D
PV14
Manual Edition: Rev 01
July 10, 2000
High Efficiency, Industrial Grade,
Alternative Energy Battery Charge Controller
for Smaller PV Systems
For Flooded Lead Acid &
Sealed Gel Battery Technologies
MODEL: PV7 & PV7D (12V & 24V)
PV14 (12V & 24V)
1217 State St., Charlevoix, MI 49720 Ph: (231) 547-9430 Fax: (231) 547-5522
Come See us at
http://www.flexcharge.com
Page2
PV7-PV14 manual.doc
WARNINGS & IMPORTANT INFORMATION
Ø
THE PV7 & PV14 CONTROLLERS ARE "ON/OFF" REGULATORS, NOT
CONSTANT VOLTAGE REGULATORS, AND THEREFORE CAN NOT BE TESTED
BY SIMPLY MEASURING THE OUTPUT VOLTAGE OF CONTROLLER. THE
CONTROLLER MUST BE CONNECTED AS SHOWN IN ONE OF THE SCHEMATICS
BEFORE IT WILL REGULATE.
Ø
READ THIS ENTIRE MANUAL TO LEARN HOW THE CONTROLLER FUNCTIONS
BEFORE CONCLUDING THAT YOUR CONTROLLER IS NOT REGULATING.
Ø
ALL WIRE TO WIRE AND CRIMP CONNECTIONS MUST BE SOLDERED OR
TREATED WITH AN ANTI-OXIDATION COATING FOR THIS, OR ANY CHARGE
CONTROLLER TO OPERATE DEPENDABLY.
Ø
THE PV7 & PV14 CONTROLLERS ARE DESIGNED FOR USE WITH SOLAR (PV)
AND OTHER CURRENT LIMITED CHARGING SOURCES. (SOURCES WHERE THE
POSITIVE AND NEGATIVE WIRES COULD BE CONNECTED TOGETHER
CONTINUOUSLY WITH OUT DAMAGING THE CHARGING SOURCE)
.
Ø
DO NOT USE THIS CONTROLLER WITH TOWED WATER AND WIND
GENERATORS, OR OUTBOARD MOTORS. IT WILL BE DAMAGED.
Table Of Contents
Page Contents
1
Cover
2
Warnings & Table Of Contents
3
Controls and Indicators
4
Features
5
Installation Precautions
6 7
Installation Instructions
8
Controller Specifications & Blocking Diode Selection Chart
9
Wiring Schematic
PV7 Charging a Single Battery Bank PV7D Charging Dual Battery Banks
10
Wiring Schematic
PV14 Charging a Single Battery Bank PV7 Expended to Charge Two or More Battery Banks
11
Wiring Schematic
PV7/D & PV14 Expanded to Charge From High Current Charging sources
12 - 13
Flexcharge Energy State Charge Method (ESCM)
14
Using Blocking Diodes (Discussion)
15
Troubleshooting Guide
16
Warranty Information
1217 State St., Charlevoix, MI 49720 Ph: (231) 547-9430 Fax: (231) 547-5522
Come See us at
http://www.flexcharge.com
Page3
PV7-PV14 manual.doc
Controls and Indictors
PV + Input
Charging
Indicator
Battery #1
Positive
Battery #2
Positive
PV7
PV7D
PV14
PV -
BAT-
1217 State St., Charlevoix, MI 49720 Ph: (231) 547-9430 Fax: (231) 547-5522
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PV7-PV14 manual.doc
Features
2 Year Warranty
Assembled in the USA using high quality surface mount components.
High charging efficiency
Charges batteries from 0 (Zero) volts with full uninterrupted power.
Expandable into a high ampere controller. Use up to 4ea 100A contactors to
regulate 400 amperes. Charge divert feature is available (Optional).
The PV7 and PV14 circuitry consumes only 4mA (0.004A).
Charges batteries at full power, below the plate saturation point. This charges
batteries quickly while reducing the electrolyte depletion (water loss) by up to
90% over conventional constant voltage methods such as PWM & High
Frequency charge regulators.
Batteries begin charging at only 0.005A of charging current.
Fuse protected.
Highly accurate voltage sensing make these controllers great for smaller, or
when expanded, for larger photovoltaic systems.
U/L 94V-O Rated Enclosure
Electronics are completely sealed and potted for use in 100% humidity
environments.
1217 State St., Charlevoix, MI 49720 Ph: (231) 547-9430 Fax: (231) 547-5522
Come See us at
http://www.flexcharge.com
Page5
PV7-PV14 manual.doc
INSTALLATION PRECAUTIONS
MOUNTING
Choose a mounting location that will not exceed 140° F., where it will be exposed to solvents such as
diesel fuel or gasoline, or be subject to excessive vibration like on an engine block. The controller
should be mounted within 5 wired feet of the battery for best performance. The controllers
electronics are sealed in a UL listed polymer epoxy making the controller completely splash proof.
NOTE: The fuse is not waterproof. Move the fuse to a protected location near the battery if the
controller will be mounted in a potentially wet environment.
SOLDERING
Always solder or use an anti-oxidation coating on all crimp and wire to wire connections. As long as
the wire connections are exposed to oxygen, they are highly susceptible to corrosion. This will cause
your unsoldered connections to degraded or fail typically within a year after the installation.
OPERATING PRECAUTIONS
Do not operate the controller with the battery wires disconnected and the solar panel(s) exposed to
light. In some rare circumstances, the controller may overheat. Shut down the solar panel, or first
disconnect the PV+ wire from the controller before removing the battery. For best results, install a
fuse in the PV+ wire near the controller as mentioned below.
WIRE SIZES
Use at least #14 AWG to #10 AWG size wire for extensions. This will allow for good charging
efficiency an accurate voltage sensing by the controller.
BLOCKING DIODES
The PV7 and PV14 controllers isolate the solar panels from the batteries when they are not
producing power. Therefore a blocking diode is not necessary on the solar panel; however, if you
are using more than one panel in parallel, place a blocking diodes in each panels + wire or junction
box. This will protect a good panel from being drained into a potentially damaged panel. Individual
panel blocking diodes should always be used on all Amorphous type panels (Uni-solar).
EXTRA PROTECTION
We highly recommended that a 10A (for PV7) or 20A (for PV14) fuse or DC circuit breaker be
installed in the orange wire between the solar panel(s) and the controller. This will offer a higher
level of protection against over charging current conditions and short circuit protection. In addition, it
will provide a convenient place to disconnect the solar panel(s) before disconnecting the battery.
Installation Tools
#6 or # 8 MOUNTING SCREWS - SCREWDRIVER - SOLDER & SOLDERING IRON
(NON GROUNDED MODEL) - TAPE or HEAT SHRINK TUBING RTV SEALER - SMALL
CRESCENT WRENCH FOR BATTERY TERMINALS - HOOKUP WIRE
1217 State St., Charlevoix, MI 49720 Ph: (231) 547-9430 Fax: (231) 547-5522
Come See us at
http://www.flexcharge.com
Page6
PV7-PV14 manual.doc
IMPORTANT
When installing the system wiring,
make sure all wire connections are making good electrical and
mechanical connection. Splice connections should be soldered. Connections that are not made
with screw tightened terminals should have anti-oxygen / anti-corrosion coatings applied to the
connections before inserting the wires.
Note: Step numbers correspond to the numbers in the installation schematics.
1.
Choose a good mounting location no more than 10 wired feet from the battery you are
charging. Although these controllers have been designed for mounting in semi-harsh locations,
mounting them in a more protected environment will help to extend the operational life.
2.
Splice a #14 to #10 AWG black wire to the BLACK BAT- WIRE on the controller, and connect
it to the BATTERY BANKS negative (-) terminal and/or the system's negative battery bus. If
you are using a smart battery fuel meter that measurers total Input to Output Amp/Hours, it will
usually have a shunt in the (-) connection to the battery. Connect the (-) wire from the controller to
the same terminal as the other loads on the shunt as shown in the meters manual.
3. Splice a #14 to #10 AWG black wire to the BLACK PV- WIRE on the controller, to the SOLAR
PANELS negative (-) terminal(s).
4. Splice a #14 to #10 AWG red wire to the RED BAT+ WIRE on the controller, a