19
4.12 Battery-Based Systems
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 4.13,
Pressurizing Systems, “Pressure switch connection”
Low-voltage disconnect function Lead-acid bat-
teries 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 significantly. 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 batter-
ies.
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 con-
troller. 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 protec-
tion 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
overcharge. 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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