Battery-Based Systems4.11
Wire Sizing for the DC circuit Wire must be sized for no
more than 5 % voltage drop at 20 A (starting). Refer to a
wire sizing chart specifically for 24 V or 48 V, or follow these
examples:
24 V SYSTEM
#10 wire (6 mm
2
) to maximum distance of 30 ft (10 m)
48V SYSTEM
#12 wire (4 mm
2
) to maximum distance of 22 ft (13 m)
Greater Lengths For each 150 % increase, use next larger
wire size.
ON/OFF switching You can switch either the primary
power to the controller, or the remote (float switch) control
circuit. For an explanation, see section 5.12, Pressurizing
Systems, “Pressure switch connection”
Low-voltage disconnect function Lead-acid batteries
can be permanently damaged by over-discharge when the
voltage falls below a critical point. To prevent this, the PS
battery system controller will turn off at low voltage, and
turn back on only after the battery has recovered signifi-
cantly. The set points are:
24V SYSTEM: OFF at 22 V ON at 24 V
48V SYSTEM: OFF at 44 V ON at 48 V
A controller in disconnect mode can be reset manually by
turning off/on, but it will quickly disconnect again if the
battery is not gaining a substantial recharge.
PS pump systems can be operated from batteries.
Install a jumper wire between terminals 6 and 7 to set the
controller to battery mode. This will de-activate the MPP-
Tracking function and activate the Low Voltage Disconnect.
Wiring Connect the battery directly to the PS controller
and NOT to the load terminals of the charger. They may
not be strong enough to deliver the load spike during
starting of the pump. The PS controller has a Low Voltage
disconnect function to protect the battery from beeing over
discharged.
Some charge controller monitor the capacity of the battery
and regulate the charging accordingly. That does not work
when the battery is connected to the PS controller. In order
to provide correct charging the charger should be set to
voltage orientated regulation. This may require a jumper
to be set in the charger. Check with the manuals of the
charger manufacturer
Overload protection Install a fuse or circuit breaker near
the power source. For either 24 or 48 V , use a 25 amp
circuit breaker (PS200 or PS600 Systems) or a time-delay
(slow blow) fuse. The purpose of this protection is for
safety in case of a wiring fault, and to provide a means of
disconnect when installing or maintaining the system. PS
controllers have electronic over-current protection against
motor overload.
CAUTION The PS controller is NOT a
battery charge controller. A charge
controller prevents battery over-
charge. It is a normal part of any
renewable energy battery charging system. Be sure
the charge controller is appropriate to the type of
batteries used. (Sealed batteries use lower voltage
settings than liquid-filled batteries.)
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