BENCH TEST PROCEDURE: PPC- D

This procedure provides a basic bench test to check the operation and calibration for the PPC-D. This procedure is designed specifically for experienced electronic technicians.

Equipment required: Digital multimeter: 0-30 volt 500 ma power supply

The PPC-D printed circuit board is coated with a water resistant coating. Use a sharp pointed probe and enough pressure to pierce the coating when making measurements.

1) Make sure there is a jumper between BATTERY VOLT SENSE (+) and BATTERY (+) and one between BATTERY VOLT SENSE (-) and BATTERY (-).

3) Unplug the Temperature Compensation accessory if so equipped. Measure the resistance between the outer and inner conductors of the temperature cable connector. It should be between 4.46 KW and 4.95 KW at room temperature (25°C).

4) Measure the resistance between the BATTERY (+) and SOLAR PANEL (+) terminals. It should be open.

5) Check the diodes connected to pins 6 and 7 of the MC1723 IC.

6) Set the power supply to the nominal system voltage (12, 24, 36 or 48 volt), current limit to 500 ma.

7) Connect the power supply (-) to the controller BATTERY (-) terminal. Connect the power supply (+) to the controller BATTERY (+) terminal and to the controller SOLAR PANEL (+) terminal.

8) Measure the voltage at pin 11 of the MC1723 IC. It should be about the power supply voltage. If it is not, suspect the unit defective and return for repair.

9) Measure the voltage at pin 6 of the MC1723 IC. It should be 7.7 +/- 0.2 volts. If it is not, unsolder and remove one end of the diode on pin 6 and re-measure. If the voltage is now correct, the controller should be sent in for repair. If the voltage is still wrong, the MC1723 is bad.

10) If the controller is in charge mode, go to step 14. If it is not, switch on and then off the ARRAY circuit breaker. The controller should go into charge mode.

11) Measure the voltage across the relay coil (smaller wires). It should be between 8.0 and 13.0 volts. If it is not, suspect the 100 ohm power resistor, Xstr TIP 100(or 102).

12) Verify the set-points by changing the power supply voltage up and down and observing the activation.

13) Change the CHARGE SET-POINT SELECT switch and power supply to verify other set-points. Repeat steps 10-13. Refer to the specifications for set-point values.