User Manual
Contents
1. The Micha Design Company Ltd Page 25 of 28 MF 10 Feb 2015 Issue 6 801265 6 doc ter Contactor Diode imi Product Manual Over Voltage L Micha Design OVL 24V 55A NE Negative Earth Common Negative Wire Routing 9 2 8 2 9 9 v V T6TOTH 967 1 0 ry xe3 1919 7 96 1 0 v APL 9007 Aueduio oq jo2. 8 Z 9 S v L 26000 9601 0 pp Xed 19196 9671 0 9007 Aueduio gt uuo d O OML Bunnoy lesum dopad 1 Xu voi 186000 Bunnow eam ve oe ura souma ipo en ML jou 31 Payu udisag e usi x wv yeu sronpoid tV nya aN WSS A8v AO Auedwio5 udiiseg euo eu p dui Ru Mb rp S30NVH3T01L 1 S1VOS WNIOINO 33423 39NVH2 ssi aiva 3nssi1sul4 go nnr 9z 193NN0260 1 1 WO9 ON ofa mm ap 88388 voL 0 201 LOL ooo OJOIO OO sees oz iz gz zz oz e ig ve 9 w u ze 9 IA CONT oto QG 29 Q IZ ez a Or O O ex ze os E m 6L s 1 n n v m 4 m OO O O O O 69 09 2 eui E O O O Q O O y 6 z ez D z D ANHE TIERE eS 310 Ear 92 NMOG zz Sri 199198 NNIWN z 8 02 S suo sr S 31
3. amos peropmp ON Pea Myr 1 13 86ldH 9png Aingseky 5peg sseuisng 8 8 E Lane gne D WSS JAO p31 Aueduio5 uSiseqg eu2i 30u 3 pa ep out em vv pumou MV gt ot pue 31 si Buymeap stu S3ONVH3TOL 31VOS TWNISINO 33823 39NVH2 SSI aiva 30891 18314 1 po Nnr ez oa Wavy Andino 1 WO2 ON Id a L d voL 0 eor LOL 9 9 The Micha Design Company Ltd ter Contactor Diode imi Product Manual OVL 48V 55A PE Positive Earth Common Positive Wire Routing Over Voltage L
4. 9 3 OJOJOJO O oolp OZ LZ 8z 22 92 V k 25 72 9 zh 6 m 8L e OL 6 m ora M Y 9 H 5 OHO Of O O O za 0t e s db le le 6L vL Sy J sa Hi 9 NO 1 MON i su o No ON OL o NO n o e OL e c V e SEHE ters c 92 Ss Giz NMOG z 9 88 i id 199135 nN3w sg oz HOTS dn IHO euo 31naow Avadsid G91 me Oni3WnN VHdTV 9L X Z 8 M StI noo OCL 10 OAW A18N3SSV ddd SDVLIOAYSAO 8 2 9 9 v L Micha Design Page 27 of 28 MF 10 Feb 2015 Issue 6 801265 6 doc ter Contactor Diode imi Over Voltage L Micha Design Product Manual OVL 48V 55A NE Negative Earth Common Negative Wire Routing 9 4
5. wuor OML 1HS bunno x JM up3314 au pasopsip d di wo v 682007 BUBno Vinci tae pl a co vw yeurenpaig UW nua AN VSS Ave TAO sun Pl usiseg euo sip piv 348 MdGs q Suivi SR Dia S3ONVH310 1 31VOS VNIOIHO 4344 359NVH2 551 INSSI 15415 Ld0 834 70 103NNOOSIG 0280 104100 ON WO9 ON Ld mm mm Ld 88 388 voL 0L zoL LOL olo OJO e ed 6 el 0z ul sz sz D z ez le m Solo e 0 O O O O m oe 8 ic z O y O O H ORAK o ole l z za ia ii 9 9 G9 9 od 9 n O f g z 72 az 9113 5 2810 bee 92 oz NMOG i r4 Q 28 r Qs 199198 NNIN eb ANG 6 an 2 6 aN JINON s O OIMAWNN WHdTV 91 X Z O nuo neo 9S0 LO ATHIWN3SSV 82d c p IOHLNOO YILIN 39V LTOAH3AO 8 L 9 v V The Micha Design Company Ltd Page 26 of 28 MF 10 Feb 2015 Issue 6 801265 6 doc 8 L 9 S v 4 L T6TOTH 9671 0 HHH xe3 1919 9621 0 p 391 9002 oq jo dd OML pops 64 004 Bunnoy M E
6. Over Voltage L Micha Design Product Manual 8 Wiring Schematics OVL 24V 55A PE Positive Earth Common Positive Wiring Schematic 8 1 8 L 9 9 v poo as 782 002 uv BUMM dd VSS Ave NX861dH 9png opted ssoursng 1 IUN 12610009601 0 xed 1919 961 0 bre PL p31 Aueduio eupr S3ONVURTOL ce vivos TVNI SIHO ma 391v NOILOnGOMd 90 Nnr ez 1 8 12 vals SH12 114110 O O0 O 5 5 wm voL za a va LOL indino wh inani eor zo Or z 0 93 ijo woo Olas 10 90 eos D Qf z 193NNOOSIG 601 S an 8 31naow Av1dsia 097 80L Quo SIMSINNN WHd TV 9L XZ SHIO palo MIO Ql 950 10 DAN A1HW3SSV 89d Y Y Y Y x 7OH 1NOO SDVLIOANSAO e e e 8 L 9 9 v V The Micha Design Company Ltd Page 21 of 28 MF 10 Feb 2015 Issue
7. High Input Voltage Alarm 1 Load Cut Disabled Low Input Voltage Alarm 1 Disabled 24V Unit 22 2V 48V Unit 44 4V UI 240V Uni ARV High Output Voltage Alarm 1 Disabled High Output Voltage Alarm 1 Set Voltage 24V Unit 30 0V 48V Unit 60 0V High Output Voltage Alarm 1 Reset Voltage 24V Unit 29 0V 48V Unit 58 0V High Output Voltage Alarm 1 Load Cut Disabled Low Output Voltage Alarm 1 Enabled Low Output Voltage Alarm 1 Set Voltage 24V Unit 222V 48V Unit 44 4V Low Output Voltage Alarm 1 Reset Voltage 24V Unit 24 0V 48V Unit 48 0V Low Output Voltage Alarm 1 Load Cut Enabled Load Cut Reset Automatic MF 10 Feb 2015 Issue 6 Page 16 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 5 Software S 1 Software History Software Version Product Manual Comments Date Released Date Issued 801 685 Ver 1 0 Issue 4 First issue of Software for PIC18F4620 Microcontroller 30 April 2010 5 Aug 2010 New Menu System with additional Alarm Menus Note Software bug found in October 2014 see Ver 1 1 801 685 Ver 1 1 Issue 5 Software bug in Software 801685 Version 1 0 30 Oct 2015 9 Feb 2015 If Regulation Mode 2 is selected Menu 6 Screen 7 then the Load Cut Contactor CTR5 only responds to the Input Voltage Set and Reset Voltages set by Menu 1 Screens 9 amp 10 It does not respond to any alarm even if the Load Cut is Enabled Menu
8. DIODE 4 DIODE 3 DIODE 2 DIODE 1 DISCONNECT 24V NEGATIVE EARTH COMMON NEGATIVE SYSTEM CTR4 CTR3 CTR2 CTR1 LOAD DIODE 4 DIODE 3 DIODE 2 DIODE 1 DISCONNECT INPUT OUTPUT O O 1 5 48V OVL Controller Configuration 48V OVL Controllers use contactors connected accros double diodes to limit the output voltage 48V PE POSITIVE EARTH COMMON POSITIVE SYSTEM 0 Ot CTR2 CTR 1 CTR4 CTR3 INPUT OUTPUT dE qd c uem LOAD 07 D 05 03 02 01 piscoNNECT 48V NE NEGATIVE EARTH COMMON NEGATIVE SYSTEM CTR2 CTR 1 CTR4 CTR3 bo oo 654 69 polos plo 1 D8 D7 D6 D5 D4 D3 D2 D1 DISCONNECT INPUT OUTPUT MF 10 Feb 2015 Issue 6 801265 6 doc Page 3 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 2 Controller Operation 2 1 2 3 2 4 2 5 2 6 MF 10 Feb 2015 Issue 6 Page 4 of 28 The Micha Design Company Ltd OVL Contactor Control PCB Assembly The PCB layout of the OVL Contactor Control PCB Assembly is shown below 200mm OVL CONTACTOR CONTROL R53 O LED3 ASSEMBLY IP P qe TD ud R54 O LED4 OPTIONAL HEADER FOR 19 RACK DISPLA i i 02 I J1 4 5 a 4855 LEDS om 00 451 41856 LEDS m4 57 imt 7 P SERIAL No 4
9. Relay 1 Function Select one of various functions Test Relay 1 Press Select to change the state of Relay 1 Display Power Screen 6 LCD Display Power Down Down Disable Disable always on Enable power down after 4 minutes Regulation Mode Screen 7 Select Mode 1 Regulation Mode Select Mode 1 or Mode 2 See Menu 1 Sections 3 6 and 3 7 Load Cut Reset may be Automatic or Manual Screen 1 If Automatic is selected then when the load is disconnected it will be reconnected after the Load Cut Reset Automatic Reset Delay time Screen 2 If Manual is selected then when the load is disconnected the user must press the Select switch to reconnect the load Alternatively if the Auxiliary Input Remote Disc 2 is set to Load Cut Reset Screen 3 then the load may be reconnected by activating the Auxiliary Input Remote Disc 2 Auxiliary Input A volt free closed contact will activate the Auxiliary Input function The Auxiliary Input can be set to Load Disconnect or to Load Cut Reset Screen 3 If set to Load Disconnect then when the Auxiliary input is active the load will be cut Alarm 1 Low Input Voltage Alarm 1 High Output Voltage Alarm 1 Low Output Voltage Alarm 1 Load Cut ommon Alarm System Normal reverse function of Common Alarm Alarm Relay 1 may be tested by using Screen 5 Q LCD Display Power Down To lengthen the life of the LCD Display it can be powered down 4 minutes after the last keypad swit
10. 1 8 2 9 S z p pius 862 004 Bunnoy am mE CMS alba bud oe S RUN Ran ata vss C puonou CV nya dd VSS Ave usiseq kuadoad ow pue 3 sj siu 1 WES S3ONVH301 31V2S TWNIDINO 33423 35NVH2 ssi ava d INSSI LSHIA pO NVf vC 1999909519 Wavuv 1ndino WODON a Ld 88 388 voL 0L zoL LoL 8 00 5 OJO kee O 6L L 02 22 bz sz L eV vc 93 ez Le 1 Q N eue O OL oe l 8 n OL vA Son AN C9 IS bos a zz o O O e O O O ea FY e 62 S l z ea E e E 7 O O o0 C IJ IO 2 O O O Lar ME Bio 8 ty cz Stes 1 6 eec 92 Ofte gs NMOG 82 iz z8 ors 1997195 nN3N v O fz 5 L oz 9198 6 6l FS O OJIN O Bt ru nio C LH O nus a21 S7 O a oOndiaWwnN vHd lv 91 X Z O O Oo SV 1S uio woo 9S0 LOY OAW A THIN3SSV 82d I3 LLIWIT J9VLIOAYXJAO 8 2 9 s v z D
11. 4 Hi I p V Alarm 1 Lo I p V Alarm 1 Hi O p V Alarm 1 Lo O p V Alarm 1 Load Cut Reset Output V 26 0V Set V 26 0V Select Disable Select Disable Select Disable Selects Enable Automatic T5 Down 4 T Bon AE down T5 Down T5 Bon 4 T Born 4 quib omn 4 Controller 24V Contactors 1 4 Hi I p V Alarm 1 Lo I p V Alarm 1 Hi O p V Alarm 1 Lo O p V Alarm 1 Load Cut Reset Common Negative Set Delay 500ms Set V 30 0V Set V 22 2V Set V 30 0V Set V 22 2V Auto Delay 30s T5 Born 4 T Bon 4 T Bon T Bon Te om T Born 4 T Down 4 Software Contactors 1 4 Hi I p V Alarm 1 Lo I p V Alarm 1 Hi O p V Alarm 1 Lo O p V Alarm 1 Auxiliary Input 801685 Ver 1 0 Reset V 23 0V Reset V 28 0V Reset V4 24 0V Reset Vi 28 0V Reset V 24 0V Not Used T5 J TY down T5 Bn T5 T Down T5 Bwn Contactors 1 4 Hi I p V Alarm 1 Lo I p V Alarm 1 Hi O p V Alarm 1 Lo O p V Alarm 1 Relay 1 Function Rst Delay 500ms Act Delay 10s Act Delay 10s Act Delay 10s Act Delay 10s Load Cut Alarm TY down T5 Down T5 Down Born 4 T5 Bon 4 Hi I p V Alarm 1 Lo I p V Alarm 1 Hi O p V Alarm 1 Lo O p V Alarm 1 Test Relay 1 Load Cut Disable Load Cut Disable Load Cut Disable Load Cut Enable Press hold Sel he own 4 Display Power Down Disable TS Bon 4 Regulation Mode Select Mode 1 3 1 Menu Navigation Navigating the menus is done by using the Menu Up and Down switches while the Select switch will activate various functions Pressi
12. 6 801265 6 doc ter Contactor Diode imi Product Manual Over Voltage L Micha Design OVL 24V 55A NE Negative Earth Common Negative Wiring Schematic 8 2 8 L 9 uv WSS Ab TAO ER p31 Kueduio eupi ou p SEA sxowvusL 1 VOS NORIO LALO 1 H1D vHLO 1 inano 0 0 O e kj K K inan voL ia za ea LOL 104100 mm 7 wm 0L ZOL ors 5 9 woo Wiuviv Q las 90 Ofe ON Q 8 LE NMOG LOANNOOSIG 601 E duas d 31033 S an 8 31naow 097 80 9 9L SMIO vMlO 419 ZULO LALO no 950 10 DAN A18W3SSV aod ri w w 70YLNO9 ADVLIOANSAO e e e e The Micha Design Company Ltd Page 22 of 28 MF 10 Feb 2015 Issue 6 801265 6 doc ter Contactor Diode imi Over Voltage L Micha Design Product Manual OVL 48V 55A PE Positive Earth Common Positive Wiring Schematic 8 3 9 s v 820 002 v
13. Reset MF 10 Feb 2015 Issue 6 Page 10 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 3 10 Menu 4 High Output Voltage Alarm 1 Settings Menu 4 Screen 0 Menu Identifier Hi O p V Alarm 1 High Output Voltage Alarm 1 Settings Hi O p V Alarm 1 Screen 1 Alarm Function Select Disable Select Disable or Enable alarm function Hi O p V Alarm 1 Screen 2 Alarm Set Voltage Set V 30 0V Voltage at which the alarm activates Hi O p V Alarm 1 Screen 3 Alarm Reset Voltage Reset V 28 0V Voltage at which the alarm de activates Hi O p V Alarm 1 Screen 4 Alarm Activation Delay Act Delay 10s Time the alarm condition must be present to activate the alarm Hi O p V Alarm 1 Screen 5 Load Cut Function Load Cut Disable Select Disable or Enable Load Cut if the Alarm is active High Output Voltage Alarm 1 Function The controller is shipped from the factory with the Alarm function Disabled To use this function the user must Enable the alarm by using Screen 1 If the output voltage is equal to or greater than the Alarm Set Voltage Screen 2 for the Activation Delay time Screen 4 then the alarm is activated If the output voltage is equal to or less than the Alarm Reset Voltage Screen 3 then the alarm is de activated The alarm may be used to disconnect the load when the alarm is activated using the Load Cut Disable Enable function Screen 5 The cont
14. Select Disable or Enable alarm function Lo I p V Alarm 1 Screen 2 Alarm Set Voltage Set V 22 2V Voltage at which the alarm activates Lo I p V Alarm 1 Screen 3 Alarm Reset Voltage Reset V 24 0V Voltage at which the alarm de activates Lo I p V Alarm 1 Screen 4 Alarm Activation Delay Act Delay 10s Time the alarm condition must be present to activate the alarm Lo I p V Alarm 1 Screen 5 Load Cut Function Load Cut Disable Select Disable or Enable Load Cut if the Alarm is active Low Input Voltage Alarm 1 Function The controller is shipped from the factory with the Alarm function Disabled To use this function the user must Enable the alarm by using Screen 1 If the input voltage is equal to or less than the Alarm Set Voltage Screen 2 for the Activation Delay time Screen 4 then the alarm is activated If the input voltage is equal to or greater than the Alarm Reset Voltage Screen 3 then the alarm is de activated The alarm may be used to disconnect the load when the alarm is activated using the Load Cut Disable Enable function Screen 5 The controller is shipped from the factory with this function Disabled To use this function the user must Enable it by using Screen 5 Load Cut occurs if the Alarm is Enabled and Activated If Regulation Mode 2 is selected this feature requires Software 801685 Version 1 1 to operate correctly see Section 5 1 Load Cut is reset Automatically or Manually see Menu 6 Load Cut
15. The controller is factory set for use with a Normally Open marked N O contact which closes to activate this means that the Normally Closed marked N C contact input is shorted out with a wire link Auxiliary Input Rem Disc 2 The Control PCB Assembly has terminals marked REM DISC 2 N O for a volt free contact to be connected When the volt free contact is closed then the Auxiliary Input is activated see Section 3 12 Menu 6 e a Micha Design Over Voltage Limiter Contactor Diode Product Manual 3 Controller Software Menus 801265 6 doc The Over Voltage Limiter OVL Contactor Diode Controller uses a microprocessor to provide control and diagnostic features in the unit A 2x16 alphanumeric LCD Display is used to show parameters and set points as described below The following diagram describes the various screens available to the user Software Menu Guide Menu 0 Menu 1 Menu 2 Menu 3 Menu 4 Menu 5 Menu 6 Menu 0 Mw Menu 1 M Menu 2 Mm Menu 3 Mm Menu 4 Mm Menu 5 Mv Menu 6 Mv Information gt Regulation gt ui I p V Alarm 1 gt Lo I p V Alarm 1 gt nui O p V Alarm 1 gt Lo V Alarm 1 gt various Settings Mien Bun d TR Bn y ieee Bun y Ju 5 Tor Bun dl T Pan de T Bun y Input V 28 0V Contactors 1
16. alarm Hi I p V Alarm 1 Screen 5 Load Cut Function Load Cut Disable Select Disable or Enable Load Cut if the Alarm is active High Input Voltage Alarm 1 Function The controller is shipped from the factory with the Alarm function Disabled To use this function the user must Enable the alarm by using Screen 1 If the input voltage 15 equal to or greater than the Alarm Set Voltage Screen 2 for the Activation Delay time Screen 4 then the alarm is activated If the input voltage is equal to or less than the Alarm Reset Voltage Screen 3 then the alarm 15 de activated The alarm may be used to disconnect the load when the alarm is activated using the Load Cut Disable Enable function Screen 5 The controller is shipped from the factory with this function Disabled To use this function the user must Enable it by using Screen 5 Load Cut occurs if the Alarm is Enabled and Activated If Regulation Mode 2 is selected this feature requires Software 801685 Version 1 1 to operate correctly see Section 5 1 Load Cut is reset Automatically or Manually see Menu 6 Load Cut Reset MF 10 Feb 2015 Issue 6 Page 9 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 3 9 Menu3 Low Input Voltage Alarm 1 Settings Menu 3 Screen 0 Menu Identifier Lo I p V Alarm 1 Low Input Voltage Alarm 1 Settings Lo I p V Alarm 1 Screen 1 Alarm Function Select Disable
17. configured for the system polarity Common Negative or Common Positive depending on how the system has been connected Configure Unit Contactor Coil Voltage and Power Saving The software can be used with 30V or 60V Contactors and with or without Power Saving If Power Saving is Enabled the ouput to a contactor is switched fully on for 0 25 second and thereafter energised at approximately 40 of the supply voltage This is achieved by switching the output drive transistor at a 40 60 mark space ratio at around 20KHz Every sixty seconds or whenever a new contactor is energised the contactors s that should be energised are powered at 10095 for 0 25 second Power Saving allows contactors to operate with reduced power consumption in the coil and so reduces heat and operating current Note Not all contactors or relays are suitable for this type of drive If it is required that a continuous voltage is required to switch the contactors or relays then set the Power Saving to Disabled Note With Power Saving Disabled the contactors which are energised will be connected directly and continuously across the battery supply MF 10 Feb 2015 Issue 6 Page 14 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 4 5 Factory Defaults Parameter Description Factory Default Setting System Voltage Polarity 24VDC Common Positive System Contactor Coil Voltage Power Saving Contactor C
18. 2 06 RIS MENU SELECT FRE i W 4 E i W ins Micha Solar Micha a Solar 270 O Ita One bray 9 c8 dr s oa 5 0r 200 bed HABD y q W DOWN 36 137 R40 R38 R30 COUNTRY OF T R of Teast ORGN U K i RH 45 e z C9 4 018 47 R48 R50 IK DOO LT 0 BATT OP JOVL INJREMOTE DISC General Assembly amp Wiring See Sections 7 8 and 9 for the Controller General Assembly and Wiring Schematics drawings Input and Output Connections The Input connections should be connected to the Control PCB Terminals marked BATT and BATT The Output Live connection positive for a Common Negative system or negative for a Common Positive system should be connected to the Control PCB Terminal marked OP TB7 Contactors Contactors 1 4 are the contactors connected across the power diodes and should be connected between the Control PCB Terminals marked COM contactor positives to CTR4 contactor negatives Contactor 5 1s the Load Cut Disconnect contactor and should be connected between the Control PCB Terminals marked COM contactor positive and CTRS contactor negative This contactor is activated for 5 seconds at first power up It will also be energised if the Remote Disconnect is active Remote Disconnect The Control PCB Assembly has terminals marked REMOTE DISC N C and N O for a volt free Remote Disconnect contact to be connected
19. 2 5 Screen 5 Software 801685 Version 1 1 fixes this bug 801 685 Ver 1 1 Issue 6 Product Manual updated to include section 4 5 Factory Defaults 30 Oct 2015 10 Feb 2015 5 2 Installation Replacement of the Micro controller Ensure that anti static precautions are taken to avoid damage to the Micro controller when handling i e touch a conductor that 15 connected to earth before carrying out the following Turn off all power to the Controller Remove the Control PCB Fascia Cover using the four plastic thumbscrews Identify the Microcontroller IC2 40 pin integrated circuit on the PCB Assembly Carefully lever out any Microcontroller presently located there by using a small flat screwdriver on both ends equally Do this carefully Identify the device to be installed Carefully handle the device without touching the legs of the device NOTE the orientation of the semi circular notch out of one end of the device NOTE which end of IC2 has a notch in the PCB socket Now insert the Microcontroller into the IC2 socket so that the notch in the device is at the same end as the notch in the socket Before pressing down on the device to mate it fully in its socket check that all pins are properly lined up with the pins in the PCB socket Press the device fully into the socket and check that no leg has been bent or missed its socket Replace the Control PCB Fascia Cover using the four plastic thumbscrews Restore power to the Controller MF 10
20. Feb 2015 Issue 6 Page 17 of 28 The Micha Design Company Ltd Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual Micha Design 6 Installation 6 1 Steel Enclosure Unit Mounting 6 1 1 The OVL is supplied in a painted steel enclosures and should be installed using the four mounting feet horizontally or vertically as shown in the diagram below 6 1 2 Ensure that the surface to which the unit will be attached is flat 6 1 3 Ensure that the fixing method employed is sturdy enough to support the weight of the Unit 6 1 4 Position the unit so that it is shaded from direct sunlight sheltered from extreme weather conditions and oriented so that the cable glands are pointing downwards 510 0 mm 490 0 mm 470 0 mm 381 0 mm 355 0 mm 329 0 mm og 100mm h 2c oS 710 0 690 0 670 0 581 0 555 0 529 0 2c e Q 4 LO M8 IN FOUR POSITIONS E A MF 10 Feb 2015 Issue 6 Page 18 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 7 General Arrangements 7 1 24V OVL Controller General Arrangement 200mm 400mm 200mm O CONTAC
21. Normally Closed Contactors are used to short out the diodes to remove them from the circuit The Controllers are designed to handle a maximum continuous current in an ambient temperature of up to 55 C 1 3 Controller Operation The control electronics are fully automatic and energise or de energise the contactors which insert or remove diodes into the output circuit in order to achieve regulation The Controllers can operate in one of two Regulation Modes Regulation Mode 1 The Controller inserts diodes into the circuit or removes them from the circuit depending on the Output Voltage The user can adjust the voltage at which diodes are inserted and the voltage at which diodes are removed from the circuit see Section 3 6 for a detailed explanation Regulation Mode 2 The Controller inserts diodes into the circuit or removes them from the circuit depending on the Input Voltage The user can adjust the set voltage and reset voltage for each contactor see Scetion 3 7 for a detailed explanation MF 10 Feb 2015 Issue 6 Page 2 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode Product Manual 1 4 24V OVL Controller Configuration 24V OVL Controllers use contactors connected across single diodes to limit the output voltage 24V POSITIVE EARTH COMMON POSITIVE SYSTEM O O CTR4 CTR3 CTR2 CTR1 INPUT OUTPUT oo 0 0 0 04 wo Dee KJ KJ KJ 66 09 LOAD
22. OVLS50A OVL100A OVL150A OVL200A Over Voltage Limiter Contactor Diode Product Manual Issue 6 Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 1 Introduction 1 1 Overview This manual describes the Over Voltage Limiter OVL Contactor Diode products listed in the following table Micha Part OVL Products Described by this Manual Painted Steel Enclosure Number height x width x depth 101 610 OVL 24V 50 Contactor Diode Common Positive Painted Steel 600 x 400 x 200 mm 101 616 OVL 24V 50A Contactor Diode Common Negative Painted Steel 600 x 400 x 200 mm 101 658 OVL 48V 50A Contactor Diode Common Positive Painted Steel 600 x 400 x 200 mm 101 659 OVL 48V 50A Contactor Diode Common Negative Painted Steel 600 x 400 x 200 mm The Over Voltage Limiter OVL Contactor Diode products are available in Kit of parts to allow a system builder to build their own controllers 101 788 OVL 24V 50A Contactor Diode Kit of parts 101 940 OVL 48V 50A Contactor Diode Kit of parts 102 042 OVL 24V 100A Contactor Diode Kit of parts 102 045 OVL 24V 200A Contactor Diode Kit of parts 102 046 OVL 48V 200A Contactor Diode Kit of parts 102 043 OVL 48V 100A Contactor Diode Kit of parts 1 2 Controller Description The OVL Contactor Diode Controllers are designed to limit the output voltage to a maximum value They do this by using the forward voltage of diodes in series with the output to drop the voltage
23. TOR CONTROL PCB ASSEMBLY o 600mm HEATSINK AS eru OVERVOLTAGE LIMITER BAD LIVE LIVE wororo INPUT OUTPUT ww d m ao GLAND DETAILS A 2 OFF HOLE SIZE 19 0 mm GLAND SIZE PG11 CABLE SIZE 5 0 10 0 mm B 4 OFF HOLE SIZE 29 0 mm GLAND SIZE PG21 CABLE SIZE 13 0 18 0 mm MF 10 Feb 2015 Issue 6 Page 19 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 7 2 48V OVL Controller General Arrangement 200 mm 400 mm r 200 mm CONTACTOR CONTROL PCB ASSEMBLY HEATSINK Tm o TO MF 10 Feb 2015 Issue 6 Page 20 of 28 The Micha Design Company Ltd 801265 6 doc ter Contactor Diode imi
24. ch press if the function is set to Enable Screen 6 Regulation Mode Select Regulation Mode 1 or 2 see Sections 3 6 and 3 7 for more details MF 10 Feb 2015 Issue 6 Page 13 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 4 Configuration Screens 4 1 4 2 4 3 4 4 NOTE The Configuration Screens should ONLY be used by authorised persons CAUTION Setting the Configuration Screens incorrectly may cause incorrect operation WARNING Setting the Configuration Screens incorrectly may result in damaging the unit Power Up Screen Contactor Over Screen 0 The Power Up Screen is shown for 2 seconds after power up Voltage Limiter To enter the Configuration Screens the Menu and Select switches should be pressed and held down when the Power Up Screen see above is shown When the first Configuration Screen is shown the switches may be released Configuration Screens Configure Unit Screen 1 Configure Unit Voltage Voltage 24V 24V or 48V Configure Unit Screen 2 Configure Unit Polarity Common Negative Common Negative or Common Positive Configure Unit Screen 3 Configure Unit Contactor Coil Voltage Cont Coil V 30V 30V or 60V Screen 4 Configure Unit Contactor Power Saving Enable or Disable Configure Unit Voltage and Polarity The software must be configured for the system voltage as shown on the Control PCB Assembly The software must be
25. cha Design Company Ltd ter Contactor Diode imi Over Voltage L Micha Design Product Manual OVL 48V 55A NE Negative Earth Common Negative Wiring Schematic 8 4 sob ae 082002 5 BuU P E um ae ty musea UW WSS 8 iir p31 Aueduuo usiseg eu r oup 11 NOILONGONd 90 2 CHYLO valo LILO Re LA LA 11 11 M M LA indino Ores lt K KK KK 1 6 wh voL ia za ea va sa 9a LOL LNdLNO wm wm INdNi coL ZOL O Ors 2 0 5 0 woo WYVIV Ors o 901 Oz Bi NMOG LOANNOOSIG 60L 10385 nnan MI S an 9 1 097 80 nuo OnM3WnN vHd V 91 X Z SALO pula MIO 12 OEL LOY OAN A18N3SSV 82d ni TOMLNOO YILININ 39 V L10AN3AO e e e Page 24 of 28 MF 10 Feb 2015 Issue 6 801265 6 doc ter Contactor Diode imi Over Voltage L Micha Design Product Manual 9 Wire Routing OVL 24V 55A PE Positive Earth Common Positive Wire Routing 9
26. en successive Contactors de energising Regulation Contactors 1 4 Set Voltage If the Output Voltage increases to be equal to or greater than the Contactors 1 4 Set Voltage then the controller energises a contactor which inserts the diode s connected across its contacts into the circuit This has the effect of reducing the output voltage by a certain voltage depending on the number of diodes connected across the contactor contacts If the Output Voltage continues to be equal to or greater than the Contactors 1 4 Set Voltage then the controller waits for the Contactors 1 4 Set Delay time and then energises the next contactor and so on until all contactors are energised Each contactor being energised inserts more diodes into the circuit and reduces the output voltage Regulation Contactors 1 4 Reset Voltage If the Output Voltage decreases to be equal to or less than the Contactors 1 4 Reset Voltage then the controller de energises a contactor which removes the diode s connected across its contacts from the circuit This has the effect of increasing the output voltage by a certain voltage depending on the number of diodes connected across the contactor contacts If the Output Voltage continues to be equal to or less than the Contactors 1 4 Reset Voltage then the controller waits for the Contactors 1 4 Reset Delay time and then de energises the next contactor and so on until all contactors are de energised Each contactor being de ener
27. gised removes more diodes from the circuit and increases the output voltage MF 10 Feb 2015 Issue 6 Page 7 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 3 7 Menu 1 Regulation Mode 2 The Controller can be operate in one of two Regulation Modes Mode 1 and Mode 2 see Menu 6 Screen 7 Menu 1 Screen 0 Menu Identifier Regulation Input Voltage Regulation Settings Contactor 1 Screen 1 Contactor 1 Set Voltage Set V 26 0V Input Voltage at which Contactor 1 energises Contactor 1 Screen 2 Contactor 1 Reset Voltage Reset V 25 0V Input Voltage at which Contactor 1 de energises Contactor 2 Screen 3 Contactor 2 Set Voltage Set V 27 4V Input Voltage at which Contactor 2 energises Contactor 2 Screen 4 Contactor 2 Reset Voltage Reset V 26 0V Input Voltage at which Contactor 2 de energises Contactor 3 Screen 5 Contactor 3 Set Voltage Set V 29 0V Input Voltage at which Contactor 3 energises Contactor 3 Screen 6 Contactor 3 Reset Voltage Reset V 27 6V Input Voltage at which Contactor 3 de energises Contactor 4 Screen 7 Contactor 4 Set Voltage Set V 30 0V Input Voltage at which Contactor 4 energises Contactor 4 Screen 8 Contactor 4 Reset Voltage Reset V 28 6V Input Voltage at which Contactor 4 de energises Cont 5 Load Cut Screen 9 Contactor 5 Load Cut Set V 22 2V Input Voltage at which Contactor 5 energises Cont 5 Load Cut Screen 10 Contacto
28. naON Av1dsla a97 Hlo nuo OruaWnN vHdTV 9 X 2 St FTO noo OEL LO DAN ATESINASSV 82d IOHLNOO S3LIIWIT39VI TlOAH3AO 8 2 9 9 v The Micha Design Company Ltd Page 28 of 28 MF 10 Feb 2015 Issue 6
29. ng Menu and Down together will take the user back to Menu 0 Screen 0 Home Pressing the Menu switch at any screen in Menu 0 will change the display to show the top screen of Menu 1 In a similar manner the user can move to Menus 2 3 4 etc and back to Menu 0 by pressing the Menu switch repeatedly The Up and Down Switches will move the user up and down within a menu 3 2 Parameter Adjustment To adjust settings at the appropriate screen press Select and the parameter will flash Use the Up or Down switches to select the desired value Press Select again to accept and store the value in non volatile memory 3 3 Power Up Screen Contactor Over Screen 0 The Power Up Screen is shown for 2 seconds after power up Voltage Limiter MF 10 Feb 2015 Issue 6 Page 5 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 3 4 Menu 0 Information Menu 0 Screen 0 Menu Identifier Information automatically goes to Screen 1 after 2 seconds Input V 28 0V Screen 1 Controller Information Output V 26 0V Input Voltage and Output Voltage Load Voltage Controller 24V Screen 2 Controller Information Common Negative Unit Voltage and Unit Polarity Software Screen 3 Controller Information 801685 Ver 1 0 Microcontroller Software Number and Version Menu 0 shows basic Controller Information Input Voltage and Output Voltage System Voltage and Polarity and the Microc
30. oil Voltage 30VDC Power Saving Enabled Regulation Mode Regulation Mode 1 Regulation Mode 1 Contactors 1 4 Set Voltage 24V Unit 26 0V 48V Unit 52 0V Regulation Mode 1 Contactors 1 4 Set Delay 500ms Regulation Mode 1 Contactors 1 4 Reset Voltage 24V Unit 23 0V 48V Unit 46 0V Regulation Mode 1 Contactors 1 4 Reset Delay 500ms Regulation Mode 2 Contactor 1 Set Voltage 24V Unit 26 0V 48V Unit 52 0V Regulation Mode 2 Contactor 1 Reset Voltage 24V Unit 25 0V 48V Unit 50 0V Regulation Mode 2 Contactor 2 Set Voltage 24V Unit 27 4V 48V Unit 54 8V Regulation Mode 2 Contactor 2 Reset Voltage 24V Unit 26 0V 48V Unit 52 0V Regulation Mode 2 Contactor 3 Set Voltage 24V Unit 29 0 48V Unit 58 0V Regulation Mode 2 Contactor 3 Reset Voltage 24V Unit 27 6V 48V Unit 55 2V Regulation Mode 2 Contactor 4 Set Voltage 24V Unit 30 0V 48V Unit 60 0V Regulation Mode 2 Contactor 4 Reset Voltage 24V Unit 28 6V 48V Unit 57 2V Regulation Mode 2 Cont 5 Load Cut Set Voltage 24V Unit 22 2V 48V Unit 44 4V Regulation Mode 2 Cont 5 Load Cut Reset Voltage 24V Unit 26 0V 48V Unit 52 0V MF 10 Feb 2015 Issue 6 Page 15 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual Factory Defualts Continued Parameter Description Factory Default Setting Unic 300V ABV Uni 600 DAV Unit 290V ABV Uni c OV
31. ontroller Software Number and Version 3 5 Menu 0 Screen 1 Input V 28 0V Screen 1A Input Voltage and Output Voltage Load Voltage Output V 26 0V Input V 28 0V Screen 1B Input Voltage Hi I p V Alarm 1 High Input Voltage Alarm 1 activated flashes on line 2 Load Cut Active Screen 1C Load Cut Activated Reset Select Press Select to Reset for Manual reset Load Cut Active Screen 1D Load Cut Activated Auto Reset 30s Auto Reset in 30 secs for Automatic reset Screen 1 normally displays the Input Voltage and Output Voltage as shown in Screen 1A If an alarm is enabled and active then line 2 of the screen will flash as shown in Screen 1B MF 10 Feb 2015 Issue 6 Page 6 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 3 6 Menu 1 Regulation Mode 1 The Controller operates in one of two Regulation Modes Mode 1 and Mode 2 see Menu 6 Screen 7 Menu 1 Screen 0 Menu Identifier Regulation Output Voltage Regulation Settings Contactors 1 4 Screen 1 Contactors 1 4 Set Voltage Set V 26 0V Output Voltage at which successive Contactors energise Contactors Screen 2 Contactors 1 4 Set Delay Set Delay Delay between successive Contactors energising Contactors Screen 3 Contactors 1 4 Reset Voltage Reset V Output Voltage at which successive Contactors de energise Contactors Screen 4 Contactors 1 4 Reset Delay Rst Delay Delay betwe
32. r 5 Load Cut Reset V 26 0V Input Voltage at which Contactor 5 de energises Contactor Output Control Each Normally Closed Contactor 1s provided with Input Voltage Set and Reset Set points Contactors 1 to 4 to be used across power diodes If the Input Voltage is equal to or greater than the Contactor Set Voltage then the Contactor is energised If the Input Voltage is equal to or less than the Contactor Reset Voltage then the Contactor is de energised Contactor 5 to be used as a Load Cut contactor If the Input Voltage is equal to or less than the Contactor Set Voltage then the Contactor is energised If the Input Voltage is equal to or greater than the Contactor Reset Voltage then the Contactor is de energised MF 10 Feb 2015 Issue 6 Page 8 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 3 8 Menu 2 High Input Voltage Alarm 1 Settings x MENU 2 EKEK Screen 0 Menu Identifier Hi I p V Alarm 1 High Input Voltage Alarm 1 Settings Hi I p V Alarm 1 Screen 1 Alarm Function Select Disable Select Disable or Enable alarm function Hi I p V Alarm 1 Screen 2 Alarm Set Voltage Set V 30 0V Voltage at which the alarm activates Hi I p V Alarm 1 Screen 3 Alarm Reset Voltage Reset V 28 0V Voltage at which the alarm de activates Hi I p V Alarm 1 Screen 4 Alarm Activation Delay Act Delay 10s Time the alarm condition must be present to activate the
33. roller is shipped from the factory with this function Disabled To use this function the user must Enable it by using Screen 5 Load Cut occurs if the Alarm is Enabled and Activated If Regulation Mode 2 is selected this feature requires Software 801685 Version 1 1 to operate correctly see Section 5 1 Load Cut is reset Automatically or Manually see Menu 6 Load Cut Reset MF 10 Feb 2015 Issue 6 Page 11 of 28 The Micha Design Company Ltd Micha Design Over Voltage Limiter Contactor Diode 801265 6 doc Product Manual 3 11 Menu 5 Low Output Voltage Alarm 1 Settings Menu 5 Screen 0 Menu Identifier Lo O p V Alarm 1 Low Output Voltage Alarm 1 Settings Lo O p V Alarm 1 Screen 1 Alarm Function Select Enable Select Disable or Enable alarm function Lo O p V Alarm 1 Screen 2 Alarm Set Voltage Set V 22 2V Voltage at which the alarm activates Lo O p V Alarm 1 Screen 3 Alarm Reset Voltage Reset V 24 0V Voltage at which the alarm de activates Lo O p V Alarm 1 Screen 4 Alarm Activation Delay Act Delay 10s Time the alarm condition must be present to activate the alarm Lo O p V Alarm 1 Screen 5 Load Cut Function Load Cut Enable Select Disable or Enable Load Cut if the Alarm is active Low Output Voltage Alarm 1 Function The controller is shipped from the factory with the Alarm function Enabled The user can Disable the alarm by using Screen 1 If the output voltage is equal to or less
34. than the Alarm Set Voltage Screen 2 for the Activation Delay time Screen 4 then the alarm is activated If the output voltage is equal to or greater than the Alarm Reset Voltage Screen 3 then the alarm is de activated The alarm may be used to disconnect the load when the alarm is activated using the Load Cut Disable Enable function Screen 5 The controller is shipped from the factory with this function Enabled The user can Disable the function by using Screen 5 Load Cut occurs if the Alarm is Enabled and Activated If Regulation Mode 2 is selected this feature requires Software 801685 Version 1 1 to operate correctly see Section 5 1 Load Cut is reset Automatically or Manually see Menu 6 Load Cut Reset MF 10 Feb 2015 Issue 6 Page 12 of 28 The Micha Design Company Ltd Micha Design 3 12 Menu 6 Various Settings Screen Description LCD Display Menu 6 Screen 0 Various Settings Load Cut Reset Screen 1 Automatic Load Cut Reset Screen 2 Auto Delay 30s Auxiliary Input Screen 3 Not Used Relay 1 Function Screen 4 Load Cut Alarm Test Relay 1 Screen 5 Press Hold Sel Over Voltage Limiter Contactor Diode Product Manual 801265 6 doc Menu Identifier Various Settings Load Cut Reset Automatic or Manual Load Cut Reset Automatic Reset Delay time 5 to 120 seconds Auxiliary Input Remote Disc 2 Input Set to either Load Disconnect or Load Cut Reset
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