PLA User Manual V1.5
Contents
1. Select Site mode If the furthest right button on the top bar shows the word LOG then select the Set Site mode command from the tools drop down list This will change the program into site mode The button will change to show the Site Number 6 Press the Site select button and set the site number to 4 The PLA site number PLCOM m A DED ORS STER e OF Sa Select Site Number 14 01 12 1207 2002 com2 2400 After setting this up you can confirm communication with the PLA by doing a Loopback test Select Loopback from the Tools drop down menu Click the Send button and the number 4 should appear in the reply window PLCOM e Gs Oi Sa v T Se A 14 03 38 12 07 2002 COM2 2400 Send Single Command Command Read PLRem i Address De Loopback 7 From the tools selection list select Program PLA The PLA programming utility window will open Read PLA Settings White PLA Settings CheckOK Chose PLA System Yoltage Baud Rate Load Disconnect On below Load Disconnect Off above Low Alarm On below High Alarm On above Mode 8 Press the Read PLA setting button and wait until the settings are read out An initial read is needed to actually load the settings in the PLA The ones initially displayed are a factory default set 9 Adjust the settings to those desired The entries will change to acceptable values when the mouse is moved from the cell or enter is pressed 10 Pr2. OM PLA Programming The PLA is programmed via its RS232 serial port using PLCOM 2 07 or later PLCOM is proprietary software of Plasmatronics Pty Ltd Setting Ranges System Voltage Adjustment range for all sets points 12V system 10V to 17V 24V system 20V to 34V 48V system 40V to 68V Baud Rates 300 1200 2400 9600 Baud How to Program a PLA 1 Connect the PLA to a source of power A 12V battery or plug pack will do 2 Connect the PLA serial port to the computer serial port using a standard IBM compatible 9pin serial cable The PLA serial port is DC isolated so the possibility of grounding problems is reduced 3 Open the PLCOM software and press the Modem setup button JUE aes Sa Eh ms 2 Modem Setup 135310 12 yy em Setup COM2 2400 4 Select the appropriate baud rate and port for the Direct connection The port number must be the same as the port you have the cable plugged into and the Baud rate must match what the PLA is set to If you do not know what baud rate the PLA is set to then it can be forced to 2400 baud This is done by placing a jumper on the two pins labeled 2400 to the right of the serial port connector Set the time delay setting at the bottom of the window to maximum 20 5 Press the Tools button to bring up the tools selection box PLCOM Belk Ges Sia a Te ap BF Se 10 13 57 17 12 07 2002 lcom2 2400 Send Single Command Command RRR Address De
3. PLA User Manual v1 5 PLA Specification The PLA allows up to 3 PL series charge controllers to work together The PLA provides a common communication interface four alarm or control channel outputs and can control a separate load control unit called an LS1 The PLA makes system performance data retrieval easier by providing a PC compatible way of collecting system total information WARNING read connection information p5 before connecting PL controllers to the PLA g k a z 5 2 5 E ke 3 PLA ALARM UNIT BATTERY SERIAL PORT Common Positive Ground Connection alarms Charge Controller computer Connection of a two PL controller system with a PLA Operating Conditions Battery Voltage Max 100V Battery Voltage Min 8V Relay Contact Voltage Max 100V Relay Contact Current Max 0 3A Supply Current Max 70mA at 11V Lower at higher voltages 22mA at 48V Ambient Temperature 20 to 60 C System Management The PLA can be used on its own or as a manager for one two or three PL controllers The PL controllers can be PL20 PL40 or PL60 versions in any combination However for proper operation the system voltages of all PL controllers and the PLA MUST be set to the same voltage Charge Mode Synchronisation The PLA keeps the individual PL controllers synchronised When one controller changes charge mode then all the other controllers follow that change This means that charging is properly sha
4. S1 due to load short circuits The LS output provides a relay output that is normally closed and opens when the load disconnect is active and the load should be disconnected This mirrors the state of the LS1 and can be used as a load disconnected alarm The load disconnect and AUX settings can be adjusted in the same manner as the alarms The PLA can operate without the LS1 but the LS1 requires the PLA to operate The AUX Output The Auxiliary AUX relay output is normally on and turns off when the battery voltage drops below the AUXoff setting for 100sec It reconnects when the battery voltage rises above the AUXon voltage for 100sec The AUX Output can be used as a non urgent alarm an output for disconnecting non essential loads or for generator control Most generator controllers require a contact closure to indicate when the generator should run When set up as an alarm the AUX output will produce an open contact when the generator should run This is the wrong way around for generator control The Mode setting allows this operation to be reversed If Mode is set to between 8 and 15 then the AUX output will be open when inactive and closed when active as is required for generator start operation Connection WARNING If PL controllers are connected to the PLA then correct connection of the PLA power is essential to avoid damage to the PL and possibly the PLA Positive Ground All PL controllers Connect the battery posit
5. dding them together A Personal Computer can interface directly with a PLA via a DC isolated RS232 serial port To communicate with a PLA PLCOM software version 2 07 or later is needed The user needs to select the site mode of operation This allows the user to communicate with each of the PL controllers or the PLA The PL connections 1 2 and 3 on the PLA are allocated site numbers 1 2 and 3 respectively The PLA is allocated site number 4 The device to communicate with is selected by setting the site number using the PLCOM site select button The following data is available from the PLA When Site 4 Battery Voltage Battery voltage as read by the PLA Charge Current Sum of the charge currents in PL 1 to 3 1A resolution Maximum 255A Load Current Sum of the load currents in PL 1 to 3 and the LS1 1A resolution Maximum 255A Charge Amp Hours Sum of Charge Ah from PL 1 to 3 for that day Max 4000Ah Load Amp Hours Sum of Load Ah from PL 1 to 3 plus LS1 load Ah for that day Max 4000Ah Bat Volts Max Battery Voltage Maximum for the day Bat Volts Min Battery Voltage Minimum for the day note Bat Max and Min scaled to the PLA system voltage and will change if the PLA system voltage setting is changed History Data Sums or averages each individual history entry and adds in the Load amp hours from the LS1 Ah figures are added all others are averaged The LS1 daily load amphours for the last 30days are stored in the PLA EEPR
6. ess the Write to PLA button to program the settings into the PLA 11 Read the settings back again to check the programming was correct The checksum window should show OK Green If the Checksum shows Bad Red then write the settings to the PLA again and read back again This should fix the problem If not there is a communication problem Check your setup and consult your dealer Note Setting changes do not become active in the PLA immediately They will become active automatically within 6 minutes Alternatively disconnect the PLA power and then reconnect Settings are updated on powerup The settings are stored in a non volatile EEPROM and so are not lost when the power is disconnected Mode Settings The operation of the PLA can be altered by use of the Mode setting in the PLA Programmer inside PLCOM The factory setting for Mode is 0 Changing the Relay Operation The alarm and output relay contacts are closed when the alarm condition is not active and open when it is active This is the usual form of operation for fail safe alarms because if the alarm connection is broken then the alarm will operate The sense of operation of any of the outputs can be reversed using the mode setting For example the AUX output can be used as a generator controller which often requires a contact closure to run eg modes 8 15 For a quicker alarm response time modes 16 to 31 can be used to make the alarms occur in 5 seconds instead of the sta
7. ettings for the PL controllers are also kept in sync so that the measuring days correspond between units The PLA uses the time on the PL plugged into socket 1 as the master The time on the other PL controllers and the PLA is corrected to be the same as the master PL1 This is done once a day when the time on the PLA gets to 11pm Note this is for PLA versions 2 2 Older versions used the PLA as the master For this to work correctly there must be a PL plugged into socket 1 To set the system time set PL1 correctly and the rest will automatically syncronise to it at 11pm Alarms The PLA has high battery voltage and low battery voltage alarms available as voltage free optical relay contacts The relay contacts are rated at 100V 0 3A The alarm state indicators are normally green and change to red when the alarm is active LS1 LOAD z CONTROL PLA ALARM UNIT LO H LS AUX 0000 SERIAL Jumper PORT 10Way Ribbon Cable PLA and LS1 Connection Separate power connection to PLA is not required The low alarm activates when the battery voltage falls below the low alarm set point for more than 100 sec continuously The low alarm deactivates again after more than 100sec above the alarm set point continuously The high alarm activates when the battery voltage rises above the high alarm set point for more than 100 sec continuously The high alarm deactivates again after more than 100sec below the alarm set point continuously T
8. he alarm points are programmed via the serial port using PLCOM version 2 07 or later software and are stored in an EEPROM within the PLA The settings are permanently stored even if power is disconnected The LS Output The LS relay output is normally on and turns off when the battery voltage drops below the load disconnect setting for 100sec The LS relay output turns on when the battery voltage rises above the load reconnect voltage for 100sec The LS output is the same as the control for the LS1 load switch The LS output can be used as an alarm output to indicate that the load has been disconnected It can also be used to switch off a load indirectly The LS1 Load Switch The PLA can operate with a separate load control unit called an LS1 This allows system low battery voltage to cause load disconnection The LS1 also measures the load current and provides fast short circuit protection The LS1 can carry up to 40A of load current The PLA directly controls the LS1 The PLA provides a signal to disconnect the load if the battery voltage is below the load disconnect voltage for 100sec continuously The load switch will turn back on if the battery voltage rises again above the load reconnect voltage for 100sec The 100sec time delays are to reduce the possibility of false disconnects due to load transients In the event of the load current exceeding 70A the LS1 will switch off the load current in about 2msec to prevent damage to the L
9. ive side ground to the terminal labeled Common Connect battery negative side switched or active to the terminal labeled Active Charge Controller Common or Ground Side PLA ALARM UNIT Charge Switch BATTERY SERIAL jumper PORT Common Positive Ground Connection Active or Switched Side If the PLA is to be used on its own then it does not matter which way the power is connected to it It will work with voltages of either polarity When first connected the PLA assumes a positive ground connection If it is actually connected as negative ground it will automatically swap to negative ground after 20 seconds The alarm and control connections are directly underneath their respective leds The three connectors for PL controllers are on the top side as is the 10 pin connector for the LS1 Note there must be a PL connected to socket 1 for correct time syncronisation Baud Rate J umper There is a jumper to the right of the serial port connection When this is connected it forces the PLA baud rate to 2400 baud This is useful if the user does not know what baud rate has been set on the PLA The PLA will be shipped with the jumper on set to 2400 baud System Monitoring The PLA makes multi PL controller system monitoring easier All the system data is collected together and the total system performance can be read by one download instead of downloading each controller and a
10. ndard 100 seconds On power up modes 16 to 31 need a minute to stabilise before they give reliable results The following table displays the effect of different Mode options NC normally closed NO normally open Mode for Mode for Low High LS AUX 100s Alarm 5s Alarm Alarm Alarm Output Output 0 16 NC NC NC NC 1 17 NO NC NC NC 2 18 NC NO NC NC 3 19 NO NO NC NC 4 20 NC NC NO NC 5 21 NO NC NO NC 6 22 NC NO NO NC 7 23 NO NO NO NC 8 24 NC NC NC NO 9 25 NO NC NC NO 10 26 NC NO NC NO 11 27 NO NO NC NO 12 28 NC NC NO NO 13 29 NO NC NO NO 14 30 NC NO NO NO 15 31 NO NO NO NO 10
11. red between controllers Without this synchronisation a multi controller system can be trapped in the boost mode indefinitely if there is insufficient charge current from any one controller to reach the boost maximum voltage setting BMAX The PLA reads the controller charge mode once each minute To cause a change in the PLA mode the new mode must be read four times in a row This is to stop false changes in mode due to electrical noise This means that the PLA will take about 4 minutes to catch up with a change in mode of one of the PL controllers When the PLA changes mode it updates the mode in each PL controller If there is an error in sending out the new system mode the PL will resend the mode information to correct the error For predictable operation the corresponding charge mode settings in each PL controller should be the same Maximum Boost Voltage BMAX Equalisation Time EMAX Equalisation Time ETIM Equalisation Frequency EFRQ Absorption Voltage ABSV Absorption Time ATIM Float Voltage FLTV Boost Return Voltage BRTN and Boost Frequency BFRQ Note The controller will not go through the Equalisation mode unless one of the PL controllers moves into that mode It will not stay in equalisation unless all the PL controllers have equalisation enabled Hence if an equalisation mode is required all PL controllers must have the equalisation mode enabled i e anon zero ETIM Time Synchronisation The time s
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