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BPR2-NGT SOLAR

REGULATOR
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

BPR2-NGT Solar Regulator

Product Manual

TABLE OF CONTENTS
1.

INTRODUCTION ............................................................................................... 3

2.

SOLAR REGULATION .................................................................................... 4

3.

LOW VOLTAGE ALARM/GENERATOR START ....................................... 4

4.

LOW VOLTAGE DISCONNECT .................................................................... 5

5.

HIGH BATTERY VOLTAGE ALARM............................................................ 6

6.

SCROLLING THE DIGITAL METER DISPLAY .......................................... 6

7.

CONFIGURING THE BPR2-NGT REGULATOR ........................................ 7

7.1.
7.2.
7.3.
8.
8.1.

SETTING THE INTERNAL PCB LINKS. ............................................................... 7


SETTING THE TIME OF DAY GENERATOR START FEATURE ............................. 8
SELECTING THE EARTHING POLARITY ............................................................. 9
INSTALLING THE BPR2-NGT REGULATOR ............................................ 9
WIRING TO THE BPR2-NGT REGULATOR ..................................................... 10

9.

TESTING THE BPR2-NGT REGULATOR ................................................. 11

10.

ADDITIONAL DISPLAY INFORMATION ................................................... 12

11.

BPR2-NGT REGULATOR SPECIFICATIONS .......................................... 13

TABLE OF FIGURES
FIGURE 1
FIGURE 2
FIGURE 3

BPR2-NGT MIMIC PANEL......................................................................... 3


CONFIGURING THE REGULATOR ................................................................ 7
WIRING INTERFACE DIAGRAM .................................................................. 10

TABLE OF TABLES
TABLE 1
TABLE 2
TABLE 3
TABLE 4

LED FUNCTIONS ........................................................................................ 3


CHARGING REGIMES .................................................................................. 4
DISPLAY PARAMETERS .............................................................................. 6
SELF-TEST FUNCTIONS ........................................................................... 12

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Benbro Electronics

BPR2-NGT Solar Regulator

Product Manual

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

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

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BPR2-NGT Mimic Panel

LED Functions

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Benbro Electronics

BPR2-NGT Solar Regulator


2.

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

REGULATION MODE TERMINOLOGY

LED

STATUS

BOOST MODE

Charging will allow the battery voltage to


rise to the boost voltage level of 2.5 (2.4)
Volts per cell (ie 15V (14.4V)1 in a 12 V
system) @ 20 C.
When the Boost Voltage has been
reached the BPR2-NGT Regulator
maintains the boost voltage for 30
minutes, to ensure all cells are 100%
charged and equalised.
Following equalisation the battery
voltage is allowed to fall to 2.4 (2.3) Volts
per cell (14.4V (13.8V) in a 12 V system)
and is maintained at this level. If the
battery voltage drops below 2.2 (2.1)
Volts per cell (13.2V (12.6V) in a 12 V
system) the BPR2-NGT Regulator will
revert to boost mode.
Battery voltages are temperature
compensated by 30 mV/C rise above
20C, in a 12 volt system, 60mV in a
24V systems, 90mV in a 36V system
and 120mV in a 48V system.

LED 14

OFF

LED 14

FLASHING

LED 14

ON

EQUALISATION
MODE

FLOAT MODE

TEMPERATURE
COMPENSATION

Table 2
3.

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.)

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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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, 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.

LOW VOLTAGE DISCONNECT


(Indicated by Red LED 11 on the mimic display.)

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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BPR2-NGT Solar Regulator


5.

Product Manual

HIGH BATTERY VOLTAGE ALARM


(Indicated by Red LED 12 on the mimic display.)

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.

SCROLLING THE DIGITAL METER DISPLAY

The display is activated by pressing the button


on the mimic display panel.
Pressing the button again will scroll the display to the next parameter. A green
LED on the mimic display indicates which parameter is currently displayed. If
the button is not pressed for 5 minutes the display will turn off to conserve
power. Ampere hour values are reset by pressing and holding the mimic button
on the front panel continuously for 30 seconds.
If LEDs 4,7, or 10 are flashing it is necessary to multiply the meter reading
being displayed by 10 to obtain the correct value.
LED
3
4

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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Benbro Electronics

BPR2-NGT Solar Regulator


7.

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, ON=0.5mV/A
Not Used
Not Used

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

Configuring the Regulator

Setting the Internal PCB Links.

(The BPR2-NGT Regulator as supplied.)


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

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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.
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

7.2.

Setting the Time of Day Generator Start Feature

To enable this feature set SW3 switch number 4 to the ON position.


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. The generator will run until either the batteries reach the boost voltage
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BPR2-NGT Solar Regulator

Product Manual

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.

Selecting The Earthing Polarity

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.

INSTALLING THE BPR2-NGT REGULATOR

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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BPR2-NGT Solar Regulator


8.1.

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

- +- +

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, 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)

Connect the battery power cables to the regulator terminal block


marked BATT and COM.

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BPR2-NGT Solar Regulator

Product Manual

c)

Connect the battery sense cables to the small terminal block


marked BS+ and BS-.

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-. NOTE: Current
polarity of the external temp sensor must be observed.

Attach the sensor to one of the cells in the battery bank


using a sensor fixing kit. The sensor should be mounted
on the side of the battery, below the permanent electrolyte
level, and in very close contact with the battery.

e)

Connect the battery power cables, including the battery sense


wires, to the battery bank.

f)

Connect the array wires to the regulator terminal block marked


A1 and COM, A2 and COM, A3 and COM and A4 and COM.

g)

Connect the load cables to the regulator terminal block marked


LOAD and COM.

h)

Should EXTERNAL shunts or generator start be required,


connect the cables to the small terminal block on the lower
printed circuit board.

i)

Generator to terminals marked LV.


Shunts to the terminals marked SH1+, and SH1-, and
SH2+ and SH2-.

It is necessary to REMOVE links J1, J2 when connecting


an external load shunt and remove links J3, and J4 when
connecting an external solar shunt from the lower printed
circuit board. (refer to Figure 3).
Reconnect the top half of the BPR2-NGT Regulator by
reconnecting the ribbon cable plug.
The ON/OFF switch can now be turned ON.

9.

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, first releasing the master reset button then

releasing the

button.

The software revision number will be displayed on turn on.

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BPR2-NGT Solar Regulator

Product Manual

There are 9 sequential test sequences. To move to the next test sequence
again press the button

on the mimic display.

To return to normal operation press the master reset button only.


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 C
7
Displays 0 or 9 for state of switch setting 1, 2 and 3 of
SW3 (0 = off, 9 = on) displayed from right to left
8
Displays 0 or 9 for state of switch setting 4, 5 and 6 of
SW3 (0 = off, 9 = on) displayed from right to left
9
Cycles through the Relays and indication LEDs.
Table 4
10.

Self-Test Functions

ADDITIONAL DISPLAY INFORMATION


a)

Faulty Temperature Sensor: Display will read 111.

b)

Faulty Battery Sense Connection: Display will read 222.

c)

Software Version Number: Display will read version number


when reset button is pressed.

a)

NOTE
Note fuse location (if required). Fuse rating depends on load size.

b)

Battery Sense connections are required in ALL installations

c)

BPR2-NGT Regulator Terminal rail will accept 16mm building wire.


Larger cables require an external junction box.

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BPR2-NGT Solar Regulator


11.

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 - 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

Note: Values in brackets () above are for non-PVStor battery settings

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Benbro Electronics