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Charge Controller Documents:
Owner's Manual HTML
Copyright © 2008 Power Planted LLC
All Rights Reserved

Charge Controller

Owner's Manual



I. Overview


This charge controller is intended to be the interface between your batteries and your charging source (i.e. wind turbine, solar panels, etc.). It provides regulation by diverting charging power to an alternate load once the batteries are fully charged. There are two modes for charging, cycling and non-cycling, and the user can set voltage levels or use default voltage level settings. The charge controller has a 'heavy load' setting that stops cycling to provide your load with maximum power and a relay lockout feature to prevent rapid on/off relay switching when the battery voltage 'rides the line.' A small ventilation fan (not included) may be added for ventilating the battery enclosure while charging. If used the fan will automatically switch on while charging and switch off while diverting.


Cycling Mode

This mode charges the battery or batteries to a set maximum voltage, then switches charging power to a diversion load. Once the battery voltage falls below a set minimum voltage, charging power is reapplied and the diversion load is turned off. This allows for complete cycling of the battery or batteries.


Non-Cycling Mode

This mode charges the battery or batteries to a set maximum voltage, then switches charging power to a diversion load. Once the voltage falls below the set maximum voltage, charging power is reapplied to the batteries and the diversion load is turned off. The relay lockout feature will prevent rapid switching when the battery floats at the trip point.


Important Note

Cycling batteries are usually charged to a higher voltage than non-cycling batteries. Consult the manufacturer of your battery if you are unsure about the maximum voltage and recommended charging pattern for your application. NEVER EXCEED THE RECOMMENDED VOLTAGE! EXCEEDING THE RECOMMENDED VOLTAGE COULD RESULT IN AN EXPLOSION!


Heavy Load Setting

This setting temporarily stops the cycling process (if in cycle mode) and bypasses the relay lockout feature. With the relay lockout feature bypassed, the charge controller will be capable of switching between charge and diversion loads very fast. When used with power tools or other inductive loads, this feature allows the charge controller to respond very quickly to accommodate heavy start-up current draw.


Fan Output

While batteries are being charged, they give off explosive gas. To reduce the risk of an explosion, batteries that are contained in any type of enclosure should be ventilated while charging. The only exception to this is an individual battery, in a battery box, stored outside away from any flame or spark source.



The size of the enclosure determines the size of the fan required. The purpose of the fan is only to remove hazardous gas, so it does not need to be very large. A one or two battery system can employ a small computer type fan which can be switched on and off by the charge controller directly. More than two batteries probably need a larger fan. In this case the charge controller can activate a relay (sold separately) that will actuate the fan. Maximum current draw from the fan connection should not exceed 460mA.


Diversion Load

The diversion load needs to be capable of dissipating the maximum possible output from your generator source. Heavy duty resistors rated well above the maximum possible output of your generator source are recommended. Light bulbs are NOT recommended because they burn out. Never leave a light bulb diversion site unattended. See www.powerplanted.com for more information on diversion loads.





II. Using Your Charge Controller

Initial Power Up

Once you have completed the installation, the unit is ready to be powered-up. This unit should have been connected to a fuse, so to turn it on, simply insert the fuse into the fuse holder.


Setup Mode

Both the yellow and red indicators should be on to let you know it is in setup mode. Decide on the type of charging you want and follow the instructions below. To return to setup mode once you exit, press and hold the button for 15 seconds, then release.


For Cycling Mode

Press and hold the button for 5 seconds, then release. The yellow indicator will turn off and the red indicator will stay on.


To Use Default Voltage Levels (High=14V and Low=12V)

Press and hold the button for 10 seconds then release. The red indicator will blink 3 times. Setup is now complete. If the yellow light comes on, the batteries are charging. If the red light comes on, the batteries are fully charged and power is being diverted.


To Set Your Own Voltage Levels

Press and hold the button for 5 seconds then release. The yellow indicator will blink 3 times and power will be switched to charge the batteries. When the batteries reach the maximum desired voltage level, press and hold the button for 5 seconds. The red indicator will blink 3 times and charging power will be diverted. When the batteries reach the maximum discharge level, press and hold the button for 5 seconds. The yellow indicator will blink 3 times and then go out. You can reset the voltage levels as many times as you like and charging power will be switched back and forth between charging and diverting each time a new level is saved. Once you are satisfied with the voltage levels, hold the button for 10 seconds and release. The red indicator will blink 3 times. Setup is now complete. If the yellow light comes on, the batteries are charging. If the red light comes on, the batteries are fully charged and power is being diverted.



For non-cycling mode

Press and hold the button for 10 seconds, then release. The red indicator will turn off and the yellow indicator will stay on.


To Use The Default Voltage Level (13.8V)

Press and hold the button for 10 seconds, then release. The red indicator will blink 3 times. Setup is now complete. If the yellow light comes on, the batteries are charging. If the red light comes on, the batteries are fully charged and power is being diverted.


To Set Your Own Voltage Level

Press and hold the button for 5 seconds, then release. The red indicator will blink 3 times and power will be switched to charge the batteries. When the batteries are at the desired voltage level, press and hold the button for 5 seconds, then release. The red indicator will blink 3 times and charging power will be diverted. You can reset the voltage levels as many times as you like and charging power will be switched back and forth between charging and diverting each time a new level is saved. Once you are satisfied with the voltage levels, press and hold the button for 10 seconds, then release. The red indicator will blink 3 times. Setup is now complete. If the yellow light comes on, the batteries are charging. If the red light comes on, the batteries are fully charged and power is being diverted.


Manually Switching Between Charging And Diverting

To manually toggle between charging and diverting while the controller is in cycling mode, press and hold the button for 5 seconds, then release.


Heavy Load Setting

To turn the Heavy Load feature on or off, press and hold the button for 10 seconds, then release. With the heavy load feature turned on, the yellow indicator will flash while charging and the red indicator will flash while charging power is being diverted.


Using Multiple Charge Controllers

It may be desirable to charge a separate battery, or bank of batteries, as your diversion load. Any number of alternate batteries, or banks of batteries, can be safely charged by using a separate charge controller for each. See www.powerplanted.com for more information.





III. Specifications

INPUT VOLTAGE:    8-15VDC

QUIESCENT CURRENT CONSUMPTION:    11mA (0.01A)

TYPICAL CURRENT CONSUMPTION:    200mA (0.2A)
(While driving one relay and
a two inch computer type fan)

MAX CURRENT CONSUMPTION:    950mA (0.9A)
(When driving 4 relays)

MAXIMUM CURRENT DRAW AT RELAY AND FAN OUTPUTS:    460mA (0.46A)


Copyright © 2008 Power Planted LLC. All rights reserved.