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Variotrack VT 65_VT 80

1. Determines the voltage applied when the battery is fully charged This voltage prevents self discharge and keeps the battery to its optimum charge level 8 3 4 4 Absorption voltage 10009 14 4V 28 8V 57 6V Determines the battery voltage during the absorption phase See chap 7 2 8 3 4 5 Equalization authorized 10017 no Determines whether the equalization phase triggered manually or automatically is allowed or not 8 3 4 6 Equalization voltage 10021 15 6V 31 2V 62 4V Determines the battery voltage during the equalization phase 8 3 4 7 Restoring the default parameters 10056 signal Sending this signal restores the original values of the VarioTrack parameters If the installer has made some adjustments during the commissioning of the installation this function does not restore the factory settings but those made by the installer 8 3 5 Management and battery cycle 10003 menu The Variolrack battery charger is designed to ensure a Ubatt battery charge as complete as possible The charge process described in detail in chapter 7 2 is managed in 4 1 2 successive phases of which only 3 are activated by default Thus the VarioTrack will carry out only phases 1 bulk 2 absorption and 4 floating according to a charge profile as per figure hereafter which represents the basic cycle This one takes place automatically The charge curve obtained this way depends on a whole t h series of parameters that
2. In case of failure of this connection the equipment turns off and the LED 3 lights up indicating the fault A permanent message requiring a validation is displayed on the RCC if present The parameter 10060 allows establishing the type of check to be carried out or the absence of check as set by default 4 7 LIGHTNING PROTECTION The VarioTrack has internal protections against lightning by mean of surge protective devices These devices have an energy dissipation capacity limited to 3 5kA 8x20 us which guarantees a certain protection level but are not a total protection against lightning According to the installation site it is highly recommended to develop a protection strategy specific to your installation The strategies depend on various factors specific to each site we recommend therefore a professional approach to this issue Manuel utilisateur V 1 0 02 17 Samlex VarioTrack Most of the time damages due to lightning generate significant costs replacement of all the electronics which are not covered by the manufacturer s warranty The connection compartment of the VarioTrack must remain permanently closed while operating Before opening check that all voltage sources battery and PV have been disconnected or switched off and wait for at least 1 minute before opening the equipment lt is imperative to close the protection cover on the connection terminals after each servicing The VarioTrack is fitted with 2 connec
3. Solar Charge Controller SAML EX EUROPE B V MPPT Solar Charge Controller Model No VT 65 VT 80 User Manual Benutzerhandbuch Manuel Utilisateur Manual Para Utilizador Please read this manual before operating your controller Samlex VarioTrack 2 V 1 0 02 User manual Samlex VarioTrack Contents 1 INTRODUCTION YA RY ME MA AY Y 5 2 GENERAL INFORMATION ami ana NF FAR bal sosa FYR EF YE FYN hansi FF FYNED 5 ym ADOOT TMS SPORE YU A ENNE Y FFY tained a 2 2 nme saim sel NAS OO NO D RW NER rl HN TN WT HY 6 2 CO UM O ua O EU 6 2 4 QUOI llin o po die a astas 6 2A lt gt e sie a ON MOTOR aa aa a HER ER RR 6 222 BUON ve IABIN YE EEE MA RR RH YN HY 2 9 NOIRE RAN e Ge e 7 S MOUNTING AND INSTALLATIOM ssccsssccsccsssecdensvacessnsvisdsasesnedeevsseeddsveseosseedtuadeadeved etetectesattensdaseevendsadosess 7 3 1 A A E E YN e 7 OZ Vias 1 A nn ia ln om e abe ay ai 8 29 MOMO DOCO RH 2 a eect 8 3 4 OO DO taa E NR HRN IN 8 341 Assembling he co lma tan model YT GO curia iii cats 9 PE A IA 10 4 Hemen olite cable comparer sei DYAL UU OND iii 10 4 2 COMES 1i 9109 og 0 CIS TN O O YA IO O Y O FR RR I FEN PT DF TREFN RR 1 4 3 gele elie lere a al OF FW _ ve YAY FFF EY YF REF FF WRN NY 12 hae a Dap edi 12 Meet le a oI IC Or FV INO SES NF YA 12 4 5 2 Parallel CONNECTION OF PV MOQUE SINO Saver NUN UYN A GAY Fa ddn 12 4 3 4
4. 22 TR e erdi 0 ge 2 ge e EE ME O ET iii 22 TL SM ape rel il COMORES O eY Hr TRAN FN NC es 25 7 3 Default battery charge cycle original settings Re 20 8 CONFIGURING THE VARIOTRACK S cccccsssssccccssccccnssscccesssccccssecccesssccceesscecceessecceesssceeeesecees 24 8 1 Configuring the equipment by means of the internal DIP switches 24 8 2 Configuring the VarioTrack using the remotecontroolRCC 02 03 25 Gal UT O E ao amala e meb ee 25 Manuel utilisateur V 1 0 02 gt Samlex VarioTrack 0 9 DESCAPIONO Ris Y ano Ide ete aa nr EI A 25 Sl CONVENTO a Ae O I FYR NR NU FRY Y O 26 O Lame IC C55 ONO ime ma aba a b lk aa a NR HT NR 26 0 29 ie eia ole sein es aile e Le A ASIN ad ee aa 26 Gk ls ee a a AS 21 8 3 5 Management and battery cycle 100031 menu 27 8 3 6 Floating phase 10004 menu 29 SMM ele geci e gt OO MONU rat 29 0930 Uc Hn ce OO MONU NN OC OU 29 637 New Cycle 10028 MENU necia 30 8 3 10 System 10038 Menu dali 9 9 4 Displaying the equipment status using the remote control RCC 02 03 32 OA Displavina me status Ol asimile UNIT SYSTEM essensa aR gt 84 2 Displaying the operating mode of the equipment eeesssssessssrrssrrrrreeeressessssssrsessrrreerressesssssses 32 GAS oki sip ie Gi gire a TIO e 32 9AA IDISOIOVING ING VGIUSS Of amuli unii SYS ET N nuria UN ala aninda EAEE 33 84 5 Displaying messages and event MISTOMY ccccsccnrsccces
5. Safe use of the photovoltaic modules ss 15 Ay Mc Mi Te IES cis LS ne ME ole Cross e aid 13 4 3 7 Parallel connection of several VOnoTTITKS samir codiciada inicias 13 4 4 Glam sula sa si e yg ras 14 S ARS PR OO INO OT a alk lk a 14 44 2 Precautions when using TNE batteries ssssssescecccccccccsssseccccssssssssseecsesceccssssseecccessssescssesess 14 a gt sia me yeka Ae Vl lt a R N MAK AN AN GO ANAR AN KANA YAN KAN YAN 15 444 Protection device of the DOTES banisi sere hek okan isik ik ar biir Bakiye Cw 15 4 5 Mies ale o kg A O A MEM AM FE NWFN 16 el EXMEnion oran ex iSLAM WR ae a 16 4 6 elimle eli el o EF A KR A MA NK YY E A AK NO 17 MP is ig an e T e tas 17 4 7 BERO NO Lc Oe RE ER 17 4 8 COMME Meco AIN ONO DIES serena FFF FR NW 18 5 POWER UP OF THE EQUIPMENT cccssscccccssssccccsssccccsssccccesssecccesseccesssccceessecceassecceeessecceasseceeaees 18 6 DISPLAY S YS TEN na sean ananas a anne laa ale aa ea a li edit dents 20 6 1 TEMS GSE UNO 14 ena on A YEN PR tod 20 6 2 kelam eig eleme ere 1e ye MOM 20 6 3 ES goleo ae ge ee 1 a 4 PR 20 6 4 dis do cos EA EN RF RC A YRR GA RF YY HA FYN NY 21 6 5 Indicator for the amount of charge 5 6 Z 9 ss 21 7 BATTERY CHARGING PROCESS ess nceenus sen GODA torino OO ideale 22 7 1 ale go l e e in is 22 7 2 B NO PR ARF ARE RR HN 22 Fal PIRON a sa O a a arc atin NT nek 22 IZ eee HO OS a HC Y a ee HR 22 lao e a INOS E EN A A A EM YRR PYAR
6. Ubat 14 4 de T appears displaying the Ibat 67 2 Ide nine consolidated values for all the phas Bulk phas ET slawel connected equipment The ill Psol lud Wg as per the same procedure described in chap 8 4 1 Moreover the units can be viewed one by one by using the arrows up down after the SET key 2x when the cursor in reverse video is pointing to the field MULTI displayed values can be selected 8 4 5 Displaying messages and event history The message system Is the same as for an Xtender inverter and the dlarm messages information are stored and displayed in the Event history window See user manual for the RCC p 30 8 4 5 1 Message list Alarm 000 low battery voltage the battery voltage is lower than 1 66V element The Variolrack continues to operate Message 012 management of the BTS temperature sensor this indication is given only if the sensor Is connected to the VarioTrack when it is energized Switch off 014 EL Over temperature the warmest point inside the equipment has exceeded 85 C The equipment stops operating It starts again when the temperature drops back to a normal value Error 016 cooling error this indication is given only if the equipment is operating when the external cooling unit has been removed or when the connection has been interrupted for an unspecified cause Switch off 020 battery overvoltage the battery voltage is higher than 2 83V element The VarioTrack turns
7. connections tightening general condition the VarioTrack does not require any particular maintenance 13 PRODUCT RECYCLING RoHS COMPLIANT 2002 95 EC The VarioTrack meet the European directive 2002 95 EC on hazardous substances and do not contain the following elements lead cadmium mercury hexavalent chrome PBB or PBDE To dispose of this product please use the service for the collection of electrical waste and observe all obligations in force in the place of purchase 14 EC DECLARATION OF CONFORMITY The charge regulator described in this manual has been designed and manufactured in accordance with the following directives and harmonized standards EMC directive 2004 108 EC Reference standard IEC EN 61000 6 3 2011 IEC EN 61000 6 1 2005 Low voltage directive 2006 95 Reference standard IEC 62109 1 2010 ROHS directive 2002 95 EC 1507 BA ZAANDAM HOLLAND Samlex Europe B V M van Veen M Je Manuel utilisateur V 1 0 02 37 Samlex VarioTrack 15 PARAMETER LIST Modified Parameter Factory value value BA 10002 Batterychargingcurent 64884 o BA 10005 Battery floating voltage at 48V CAN BA 10008 Absorption authorized es BA 10009 Battery absorption voltage at 48V WW Ex 10011 Absorption period F120 min Ex 10013 Final current of the absorption phase 104 BA 10017 Equalization authorized NO EX 10019 Equalization before absorption phase Yes EX 1
8. cycle such as backing up and restoring the system resetting monitoring setting etc 8 3 1 Convention Functions and values of the parameters mentioned in this manual are described in this chapter Each parameter is defined by a short description a number xxxxx followed by its value and unit by default xxxxx The type of parameter menu signal replaces the value between brackets when this latter does not exist The RCC menus are also identified by a name and a number xxxxx that can be found as per the parameter number on the top right hand corner of the RCC screen 8 3 2 Parameter access level All the parameters described hereafter are accessible through 2 different access levels In factory configuration only a few of them are accessible through the basic menu To access all the other menus and parameters the RCC must be configured at the Expert level following the procedure given in the REC manual chapter USER LEVEL p 22 Each parameter can be placed at a different level for example from level Expert to level Basic In this case the parameter is accessible also when the RCC is set to basic mode For more information on this subject refer to chapter INSTALLER LEVEL OF USE AND ACCESSIBILITY p 39 in the REC manual 8 3 3 Organisation of the configuration menu Level User ref Parameter MENU 10000 BASIC SETTINGS see chap 8 3 4 Basic 10001 Voltage of the system Basic 10037 Synchronisat
9. for a certain period to finish charging The equalization phase can be interrupted when the battery charging current goes under a certain threshold This can be used in order to reduce the egualization duration and the electrolysis phenomenon related to it 8 3 8 9 Final current of the equalization phase 10027 no Determines the current under which the equalization phase is considered finished When the charger current goes below this value the next phase starts 8 3 8 10 Egualization before absorption phase 10019 yes This parameter determines if during the charge cycle the equalization will take place before or after the absorption phase By default the egualization phase is carried out before the absorption phase Ubatt V t h A equalization voltage B absorption voltage C floating voltage 8 3 9 New cycle 10028 Menu Usually batteries are charged during the day via the PV generator then partially discharged during the night by the user The next day a charge cycle starts again bulk absorption floating The conditions to restart a full cycle are met when the battery has lost some of its power because of the users who are connected to it These conditions are set by parameters from 10030 to 10033 If these conditions have not been met because for example the installation has no users a new absorption phase will not be necessary as this would lead to a slight battery water consumption In this case the char
10. off If starts again when the voltage returns to a normal value Error 80 no battery or polarity reversal the battery voltage is lower than 7 V This can be due to the absence of the battery a highly discharged battery or a polarity reversal Alarm 81 PV earthing fault the battery earthing does not anymore match the selection made by parameter 10060 which establishes the type of earthing to be checked Alarm 82 PV overvoltage the solar generator has a voltage higher than 145V when connected to a 24 or 48V battery Caution in a 12V system the max permissible voltage for a PV generator is 80V When a higher voltage is applied the VarioTrack switches off and the supply to the accessories connected to the communication bus is interrupted Message 83 no solar production for 48h no PV voltage has been detected for 48H The PV generator has probably been disconnected Check the protection devices fuse or circuit breaker and or check the wiring Message 84 egualization carried out indicates the end of the equalization cycle Manuel utilisateur V1 0 02 33 Samlex VarioTrack 9 ACCESSORIES 9 1 REMOTE CONTROL AND PROGRAMMING UNIT RCC 02 03 This accessory is an important complement to the VarioTrack lt can be connected via one of the two communication connectors Com Bus 7 see chap 4 1 Elements of the cable compartment thanks to the cable supplied with the remote control These connectors must be u
11. right to make any modifications to the product without prior notification Samlex is not liable for incidental direct or indirect damages of any kind including any profit loss revenue loss or damages caused to equipment or goods due to defective equipment 2 5 WARNINGS AND GUIDELINES The installation and commissioning of the Variolrack must be entrusted to skilled and qualified personnel perfectly aware of the safety precautions and local rules in force All elements connected to the VarioTrack must comply with the laws and regulations in force HIGH VOLTAGE DC INSIDE THE CHARGE REGULATOR DANGER OF DEATH When the Variolrack is under operation it generates voltages that can be potentially lethal up to 150Vdc Any work on or close to the installation must be carried out only by thoroughly trained and qualified personnel Do not try to carry out ordinary maintenance on this product yourself While working on the electrical installation it is important to make sure that the source of DC voltage coming from the battery as well as the source of DC voltage coming from the photovoltaic generator have been disconnected from the electrical installation Even when the VarioTrack has been disconnected from the power sources a potentially dangerous voltage may remain at the terminals To eliminate them you have to wait for at least 120 seconds in order to allow the electronics to discharge The task can then be carried out safely No person is
12. to an open battery without eaudlization with an absorption voltage of 214 4 28 8 57 6V during 2h and a floating voltage of 13 6 27 2 54 4V The parameter values can be modified using the RCC and are stored and applied by the VarioTrack When parameter 10054 is set to yes the DIP switches remain disabled even when the remote control and the communication module are removed after the settings have been entered This allows to establish the operation of the installation and to prevent any further modification using the DIP switches 8 2 1 The real time clock The VarioTrack features a real time clock that allows among others to have a correct date and hour for the RCC records This clock must be set using the remote control RCC 02 03 Thanks to an internal battery this setting is retained even when the equipment is disconnected from its voltage source battery or PV 8 3 DESCRIPTION OF THE VARIOTRACK PARAMETERS The parameters of the VarioTrack can be modified in the menu VarioTrack MPPT setting of the RCC remote control This menu allows accessing the following 3 under menus BASIC MENU where the most common parameters to be set when commissioning are found BATTERY MANAGEMENT AND CYCLE where all the parameters can be set defining in detail the Manuel utilisateur V 1 0 02 25 Samlex VarioTrack battery cycle during all its phases SYSTEM MENU gathering a few parameters that are not directly related to the battery
13. wall mounting whereas the RCC 03 is designed for board mounting Model RCC 03 must be removed from the board to access the SD card slot during updating for example Ref no dimensions H x L xl mm RCC 02 170 x 168 x 43 5mm RCC 03 130 x 120 x 42 2mm 34 V1 0 02 User manual Samlex VarioTrack Both remote control models are supplied with a 2m cable Cables of specific lengths 5m 20m and 50m can be ordered Item reference CAB RJ45 8 xx The length in metres is specified by xx 2 or max 3 within the same system remote controls RCC 02 03 or Xcom 232 can be connected in series to the communication bus of a same Variolrack In a system composed of a single VarioTrack the connection of the RCC 02 or RCC 03 may be done without stopping the eguioment hot plug When connecting an RCC 02 03 remote control in a multi unit system all the units in the system must be turned off and the termination of the communication bus where the connection is being made must be modified The termination switch of the communication bus Com Bus 8 remains in position T terminated except when both connectors 7 are used In this case and only in this case the switch must be placed in the O open position towards element 9 If only one of the two connectors is used the termination switch 8 will be in position T 9 2 TEMPERATURE SENSOR BTS 01 The operating voltages for lead batteries vary depending on the temperature A temp
14. 0020 Batteryequalizationcurent er 10021 Battery equalization voltage at 48V zav 10022 Battery equalization period mn 10025 Days between equalization B days 10026 End of equalization triggered by curent Ne 10027 Final current of the equalization phase 10 AS 9 a Ld NOA IS Y 8 O 10034 Maximum limit of the cycle repetition No 10035 Minimum period between cycles h 10037 Synchronization of a battery cycle with an Xtender Yes 10054 Inhibiting the configuration made by DIP switches No 10060 Checking the earthing system No A These values are meant for a 48V battery system They must be divided by 2 if the battery rated voltage is 24V and by 4 if the battery is 12V BA EX EX EX EX EX EX EX EX EX EX EX BA EX EX X E NO es DA No 1h NO NO 40 V1 0 02 User manual Samlex VarioTrack 16 TECHNICAL DATA 16 1 INPUT PV GENERATOR Max current of the solar generator Max voltage of the solar generator with a 12V battery 80V dc ei voltage of the solar generator with a battery gt 150V dc Max power of the solar generator 1000 2000 4000W 1 1250 gt 000W Peak efficiency Own power consumption operating night lt 5W lt 1W lt 5W lt 1W 1 In order to meet the National Electrical Code NEC in force in the United States the maximum current for the solar generator is 52A for the VarioT
15. HNICAL DATA eu ie eya ll GN dn la aa ola NA ayas ala ale daa ae md CGG 41 16 1 te al ek e ico A EY ER EYE FFR YE 4 LA a o EF Y A es hs A A 4 RA e RR AM NO RA CY DANA 4 sre e OOT UO _ RR NE a ar A1 V NOTES ea Y ER LD FRY ee D ee FFF 42 A V 1 0 02 User manual Samlex VarioTrack 1 INTRODUCTION Congratulations You are about to install and use an apparatus from the Variolrack range You have chosen a high tech equipment that will play a central role in the energy production of your solar electrical installation The VarioTrack has been designed to work as a solar battery charger its advanced and completely configurable functionalities will guarantee a perfect functioning of your energy system When the VarioTrack is connected to batteries and photovoltaic panels it automatically recharges batteries in an optimum way with all the available solar power The accuracy of the algorithm for searching the maximum operating point the high output and a low internal consumption insure an optimal valorisation of the energy produced by the solar modules The charge profile may be set freely according to the battery type or the operation mode The charging voltage is corrected depending on the temperature thanks to the optional external sensor BTS 01 The remote control and programming unit RCC 02 03 optional allows an optimal setup of the system and guarantees the user a permanent control over all important parameters for t
16. Wiring error Polarity reversal of the solar generator on its input Polarity reversal of the battery on the battery input The battery is connected No indication to the solar input Reverse connection of Notification on the VarioTrack RCC 02 03 remote control No PV voltage RCC If no battery on the input gt Message 80 LED Night 1 lit LED error 3 flashes 7x Symptom Action to be taken correction to be made Check and correct the wiring error Check and correct the wiring error Check and correct the wiring error The equipment does not switch on The internal protection fuse is broken and must be replaced by qualified personnel The wiring must be corrected The equipment functionalities must be checked Acknowledge the message and correct the wiring error The solar generator is connected to the battery input Reverse connection of the solar generator to the battery input The battery is not connected and there is an active solar generator Battery with inactive solar generator not connected or defective the battery to the solar LED error 3 Message 20 flashes 4 times input LED Night No PV voltage 1 lit isplayed on the RCC Message 80 Message 83 Message 82 Check and correct the wiring error LED error 3 flashes 7 times Acknowledge the message and correct the wiring error LED error 3 flashes 6 times The battery has no
17. arallel The compatibility of the new units can be checked by Samlex if the serial numbers of the equipment of the existing installation are provided Equipment belonging to the same system must be equipped with the same software version Download the latest software version from the manufacturer s website and update the software for all units of the system before commissioning 16 V1 0 02 User manuol Samlex VarioTrack 4 6 EARTHING GUIDELINES The VarioTrack is a Class protection equipment its metal case must be earthed by means of the screw provided between the cable gland GL protective earth connected to the enclosure of the equipment Inside the equipment the negative poles of the battery and of the PV are in common For security s sake the VarioTrack requires the negative pole to Class I be earthed The solar generator as well as its wiring must be Class ll Connect PE isolated All the other earthing systems earthing by means of a protection device impedance without earthing IT or earthed at positive pole require the whole battery circuit to be protected against electric shocks Any accidental contact with the conductive parts of the battery circuit is to be avoided by providing a Class Il protection level If the no load voltage of the panel is above 75V in all the temperature range the whole solar system must be installe
18. are connected directly to the battery through their own protective device Lead batteries are usually available in 2V 6V or 12V blocks In most cases in order to get the correct operating voltage for using the Variolrack 12 24 or 48V several batteries must be connected in series The capacity of the batteries can be increased using a parallel connection of several battery strings Some battery manufacturers limit the use or advice against the battery parallel connection Strictly conform to the manufacturer s instructions of use In multi unit systems all the VarioTracks of a same system must be connected to the same battery bank 4 4 4 Protection device of the battery The battery cables must also be as short as possible The recommended cable cross section is 25mm and the protection devices battery side must be of 80A for model VT 65 and 100A for model VT 80 The protection device must be installed the closest possible to the battery The recommended cross section is valid for length of max 3m Beyond this length it is recommended to oversize the section of the battery cables Any other sources or loads existing on the battery must be connected using their own protection devices Never connect them to the protection device s of the VarioTrack Manuel utilisateur V 1 0 02 15 Samlex VarioTrack 4 4 4 1 Internal fuse The VarioTrack has an internal fuse only on the positive terminal of the PV connection This device prote
19. ating limits of the VarioTrack In motor vehicles or when the support undergoes significant vibrations the VarioTrack is to be mounted on anti vibration elements The VarioTrack enclosure is fitted with a support plate to be mounted on the back of the case using 4 screws M and washers see fig hereafter before wall mounting Mount it vertically with the cable glands downward An external cooling fan ECF O1 can be installed before or after the eguipment has been mounted on the wall in order to improve its performances 9 V1 0 02 User manuol Samlex VarioTrack 20cm scm Yad TTT WY 205 mm 3 4 1 Assembling the cooling fan model VT 80 The VarioTrack having the reference VT 80 is supplied with an external cooling fan module ECF 01 This module can be installed before or after mounting the VarioTrack on the wall see also chap 7 3 p 39 The case of the Variolrack can reach a temperature higher than 60 C when used for a long period at maximum performance This high temperature can last several tens of minutes after the equipment has been turned off Install it in a restricted access area away from children or any unauthorized person Manuel utilisateur V1 0 02 9 Samlex 4 VarioTrack WIRING The connection of the VarioTrack charger is an important step during the installation It may be carried out only by personnel qualified and aware of the rules and regulations in force The installation mus
20. ation 10011 120min Use this parameter to set the absorption duration The absorption phase starts once the set tension 10009 is reached When time is over see chap 2 2 the charger goes automatically to the following authorized phase 8 3 7 5 End of the absorption triggered by the current 10012 no The absorption phase can be interrupted when the battery charging current goes under a certain threshold This can be used in order to shorten the period under which a high voltage is applied and thus reduce water consumption 8 3 7 6 Current threshold to end absorption phase 10013 10A Sets the current under which the absorption phase is considered finished When the charger current goes below this value the next phase most often the floating phase starts If the production of the 29 V1 0 02 User manuol Samlex VarioTrack PV generator is insufficient to keep the voltage this current is not taken into account and the absorption phase goes on Progressively during the absorption phase the charging current decreases naturally If the bulk phase has been carried out with a current appropriate for the battery it is not necessary to wait for a certain period to finish charging 8 3 8 Equalization phase 10016 menu Some types of battery need equalization in order to avoid the stratification of the water and acid they contain Use the parameters hereafter to set the operating conditions of this charging phase as descri
21. authorized to proceed with any change modification or repair of the equipment without the prior written authorisation of Samlex Use only original parts for any authorised modification or replacement Do not excess the maximum rated characteristics of the equipment shown on the Type label 3 MOUNTING AND INSTALLATION 3 1 STORAGE The equipment must be stored in a dry environment at an ambient temperature between 209C Manuel utilisateur V1 0 02 7 Samlex VarioTrack and 60 C Store if in the location where it is to be used a minimum of 24 hours before commissioning in order to avoid thermal shocks and condensation problems 3 2 UNPACKING When unpacking check that the VarioTrack has not been damaged during transportation and that all accessories listed below are present Any fault must be immediately reported to the product distributor or the contact mentioned at the back of this manual Check carefully the packaging as well as the VarioTrack Standard accessories e Installation and operation manual e Mounting plate e Cable glands for battery and PV cables 3 3 MOUNTING PLACE The mounting place for the VarioTrack is particularly important and must fulfil the following criteria e Protected from any unauthorized person e In mobile applications it is important to select a mounting place that ensures no vibration e Protected from direct solar radiation or heat sources The VarioTrack have a high degree of protection IP 54 T
22. bed in chap 7 2 4 During an equalization phase an emission of a highly explosive gas occurs hydrogen oxygen Follow carefully all the instructions of the battery manufacturer regarding this phase In any case make sure that the battery room is adequately ventilated Equalization reduces the battery water level check it regularly 8 3 8 1 Equalization authorized 10017 no Determines whether the equalization phase triggered manually or automatically is allowed or not 8 3 8 2 Forcing an equalization 10018 signal Use this parameter to start manually the equalization phase It is possible to force an equalization phase only when it is authorized by 10017 Once egualization phase is initiated disabling the phase does not stop the egualization To stop the equalization forcing the transition into floating 10006 forcing the absorption 10010 or forcing a new cycle 10029 It is also possible to interrupt the equalization by pressing the SET button for more than 2 seconds procedure described in chap 6 1 8 3 8 3 Battery egualization voltage 10021 2 6V element 15 6V 31 2V 62 4V Determines the maximal voltage during the equalization phase This voltage is corrected by the temperature correction factor 10036 if a temperature sensor BTS 01 is installed in the system 8 3 8 4 Battery equalization current 10020 80A The equalization phase can be carried out with a limited current that can be adjuste
23. cided upon it will be distributed among one or more solar charge regulators wisely combining the modules among them These combinations in series and in parallel must be carried out according to the voltage and current limits of the VarioTrack regulator 4 3 2 Serial connection string of PV modules To get the optimum voltage the solar modules shall be connected in series to form a string having the desired voltage The optimum operating voltage of the module string Umpp must always be above the battery voltage To establish the minimum number of PV modules to be connected in series in the same string the max voltage of the battery Ubat must be multiplied by 1 1 and divided by the modules Vmpp voltage For example in a system with a VLA type lead acid battery supporting equalization at 60V 60 1 2 17 4A 2 The result must be rounded up to the highest value i e 5 modules of 17 Umpp in series for the above example The open circuit voltage of the string must be lower than 150V under any temperature and irradiation conditions A 10 to 20 margin is recommended in order to cover these unknowns To establish the maximum numbers of the PV modules connected in series in the same string use the following formula 150V Uoc 1 1 Example 150 22 1 1 6 2 The result must be rounded down to the lowest value i e 6 modules of 22 Voc in series for the above example There should be thus 5 or 6 PV modules in series of the mentioned mo
24. configuration can be done using the DIP switches 9 inside the equipment see chap 8 1 7 2 BATTERY CYCLE The VarioTrack is a fully automatic solar charge regulator designed to guarantee an optimum charge for most of the lead liquid acid lead gel or AGM batteries The battery charger enters automatically into operation as soon as the irradiation is sufficient and the photovoltaic panel voltage is higher than the battery voltage The Charge indicator 2 lights up or flashes depending on the ongoing charging phase The batteries can be fully charged by the successive phases to 4 described hereunder 7 2 1 Bulk phase The bulk phase is the stage when the voltage of the battery rises thanks to the maximum available current produced by the photovoltaic generator depending on the current irradiation It is limited to a maximum of 65A for model VT 65 or to 80A for model VT 80 a VT 63 fitted with the external cooling fan ECF O1 The current can also be limited with parameter 10002 maximum output current It is possible that these currents are not reached if the generator power is not sufficient because of its dimensioning solar power silicon temperature crystalline cell or because the ambient temperature is excessive or the ventilation is insufficient t h 7 2 2 Absorption phase This charging phase of a limited duration 10011 allows the battery to absorb a maximum of power while limiting its voltage 10009 As s
25. connected to a standard earth electrode TI T2 Protective earth for the battery The battery negative pole must be earthed The other configurations must meet the recommendations at chap 4 6 T3 Protective earth for the solar The protective earth for the PV generator and its lightning generator protection device are connected separately to the main protective earth local eguipotential bonding T4 Protective earth for the Most often within a hybrid installation it is recommended generator or the AC source to connect the earthing of the whole frame and the earthing of the lightning protection device to the main protective earth T U AC wiring related to the See chap 10 1 Xtender not described in this Manuel utilisateur V 1 0 02 37 Protective earth for the The equipment is designed to be connected to a equipment protective earth Class I to which they must be connected Samlex VarioTrack E manval Wiring related to the BSP not See A AAA 8 8 22 10 2 AA in this manual National installation standards specific to the chosen application field must absolutely and as a priority be respected under the installer responsibility 11 3 VARIOTRACK XTENDER RCC 02 BSP BTS OTHYBRID SYSTEM PV anemi PV ENT 38 V1 0 02 User manual Samlex VarioTrack 12 MAINTENANCE OF THE INSTALLATION Except for the periodic check of the
26. connection The VarioTrack turns off If automatically starts again when the normal situation is restored Flashes Power reduction or stop This may be due to an excessive ambient temperature 05 due to an excessive exposure of the equipment to a heat source sun or to temperature in the deficient or mpeded ventilation equipment Flashes Battery voltage higher Check the cause of this excessive voltage The O O O O O A N AX than 17 34 68V equipment automatically starts again when voltage returns to a value lower than 17 34 68V Flashes The PV voltage is higher The PV voltage exceeds the max limit of 145V 75V 5 than the set value of the when battery is 12V The equipment will stop or won t max operating limit start X Flashes No voltage has been The PV generator Is probably disconnected Check the 6X detected since 48h protection devices fuse or circuit breaker and or check the wiring Check the internal fuse 5 CD NO X gt lt V Flashes Software incompatibility in The software version of all equipment of the system a multi inverter system must be the same Proceed with the update following the procedure in manual RCC 02 03 Flashes Connection error between the equipment Check the 11 ox between the units presence and state of the communication cables between the units If the internal fuse is broken this shows a major error in your wiring most probably either a short circui
27. cts the equipment against short circuits on the PV side when the equipment is operating charging and against a battery connection error A broken internal fuse is a sign of a major fault in the wiring most probably either a short circuit on the solar generator side or a battery reverse connection on the solar input In such case check carefully the equipment operation after having corrected the fault The fuse is composed of 4 fuse links 30A 80V that must be replaced by the same type of fuses i e Littlefuse Ref FKS 166 7000 530 or similar This operation must be carried out by a dudlified personnel In case of doubt the equipment must be returned to the supplier tor a check this fault is not covered by the warranty An annual check of all the connection tightness is recommended On mobile installations the connection tightness should be checked more often Battery cables must always be protected by one of the following measures Have a protection and disconnection device fuse circuit breaker on each pole or only on the pole not connected to earth The protection device must be rated according to the cable cross section but must not exceed 1 25 x Variolrack maximum current It will be mounted as close as possible to the battery 4 5 MULTI UNIT CONFIGURATIONS Several interconnected VarioTracks See chap 4 3 7 may be used on the same battery to create a high power charger In multi unit systems the units are interconnected
28. d according to class of protection ll The cross section of the earthing cable must not be lower than 16mm2 In any case the protective earth must be connected in accordance with local standards and regulations in force The protective earth of the equipment must be connected at least to the protective earths of all the Class equipment after and before the Variolrack equipotential connection The information notes recommendations and diagrams reported in this manual are in any case subject to local installation rules The installer is responsible for the conformity of the installation with the local standards in force Never earth the positive pole of the solar generator and the positive pole of the battery within a same installation Do not connect the positive pole of the solar generator to the earth otherwise dangerous voltages will surge between the battery poles and the earth If required by functionality like with the Sun power PV modules The positive pole of the solar generator could be earthed thru a 100k0 1W resistance Then it is mandatory to insure protection against electric shock by mean of battery earthing Class I or class ll on the whole battery circuit 4 6 1 Detecting an earth fault Choosing how to earth the DC circuit is an important factor for the individuals safety Once made the choice the Varolrack can check the continuity or on the contrary the failure of the earth connection in the case of IT system
29. d to observe all the safety instructions and indications herein This manual does not contain any information meant for persons other than the personnel qualified for the installation of such a product The installation and commissioning of the VarioTrack must be entrusted to qualified personnel The installation and use must comply with the local safety instructions and standards in force in the country 2 3 CONVENTIONS This symbol is used to indicate safety instructions which If not followed could result in serious personal injury or death to the operator or the user This symbol is used to indicate a risk of material damage and or the cancellation of the guarantee This symbol is used to indicate a procedure or function that is important for a safe and correct use of the equipment Failure to respect these instructions may lead to the cancellation of the guarantee or to a non compliant installation In general values important for the operation of the equipment for example battery voltage during absorption are not mentioned and the parameter number is indicated in the following format xx The value of the parameter can be found in the table chap 15 In most cases these values can be modified with the remote control RCC 02 03 see chap 9 1 The parameter table available at the end of this manual p 40 must be kept updated in case the parameters are modified by the operator or the installer If an authorised person mod
30. d using this parameter In any case the current does not exceed the bulk current 10002 As a rule the limited charging current is used only if the egualization is started at the end of the absorption phase 8 3 8 5 Equalization period 10022 30min Determines the equalization period The equalization phase starts as soon as the set voltage 10021 is reached When the period has elapsed the charger goes automatically to the following authorized phase If the voltage cannot be kept no sunshine clouds the countdown is interrupted 8 3 8 6 Equalization at a fixed interval 10024 yes When this parameter is activated yes the battery charge cycle with an active equalization phase starts at the interval soecified by the following parameter 10025 8 3 8 7 Days between the equalizations 10025 26 days Determines the number of days between each equalization This counter is reset to zero when the equalization is activated manually In the case of incomplete charging cycles for example when charging with solar generators this function is useful also to limit the repetition of the equalization cycles Manuel utilisateur V 1 0 02 29 Samlex VarioTrack 8 3 8 8 End of the equalization friggered by the current 10026 no Progressively during the equalization phase the charging current decreases naturally If the bulk phase has been carried out with a current appropriate for the battery It is not necessary to wait
31. del for a 48V system as per this example The table hereunder gives an idea of the possible arrangements for common panels according to the number of cells or their type 36 cell 60 cell 72 cell Thin layer module module module module Voc lt 23V Voc lt 37V Voc lt 45V Voc gt 80V semen max opt max om max opt a 2 21l 1 o Numberot Cu EEE EE a module Beware of the PV module temperature The above values are for modules under standard test condition STC 4 3 3 Parallel connection of PV module strings Maximum To get the required charging power 2 or more strings are usually to be recommended power for connected in parallel Each string connected in parallel shall be the solar generator composed by the same number of modules of the same type The number of strings connected in parallel depends on the power of each module The sum of the power of all the panels connected to a Variolrack should not exceed the power that the VarioTrack can charge see table hereafter The number of strings to be connected in parallel must not exceed the maximum power see table hereafter divided by the power of a string For example in a 48V system with strings composed of 5 in series modules of 100W connected to 12 V 1 0 02 User manual Samlex VarioTrack model VT 65 4000 500 8 gt 8 strings 4000W can be put in parallel These strings of 5 modules in series may become 10 when connected to model VT 80 I
32. ea Ex ae 10 20A Egual 3x Charge light indicator flashes 3x as long as 5 the egualization phase is not completed The equalization can be interrupted by pressing a second time for 2 seconds a double beep indicates that the function has been cancelled The indicator 2 stops flashing 3x confirming the cancellation Pressing the Set key 4 for 5 seconds turns off the VarioTrack If starts again by pressing the Set key for 5 seconds When the Variotrack s are connected to an Xtender system and the synchronization 10037 is activated the manual equalization can be started only during the battery cycle of the Xtender which will then pilot the VarioTrack to carry out an equalization phase In synchronized mode the cycle state floating absorption equalization is not indicated Only the charge LED 2 and the indicator for the amount of charge are used when the equipment is operating 6 2 NIGHT STANDBY INDICATOR 1 This green indicator lights up when the VarioTrack is connected to a battery and ready to operate but there is no PV voltage at night or when no PV module is connected or below This indicator flashes when there is a PV voltage but it is insufficient to charge the batteries at the beginning or at the end of the day In order to save the battery power the Variolrack charger turns off and goes in standby mode when this indicator lights up or flashes It will then consume
33. eessoecencdcoracncdeeesoacdenssoondeaavensdectanccisbaseedesssacates 33 9 ACCESSORIES imla ale Sl ie dale ae ama dalaman E a Moana Madam a ENEIT Ea 34 al Remote control and programming unit RCC 02 03 uu rss 34 9 2 Temperature sensor BIS O1 a FEN A FEED EF RD FD 39 9 2 1 Connecting the temperature sensor BTS 01 ooooccccccncnnnncnnnononanananaccccccnonanononononananananinoss 30 7 dila sike 0 0 are Tan ESP cnica da idad NT HN 39 10 EQUIPMENTS COMPATIBLE WITH THE VARIOTRACKG oooocccocooccconcocccnonicccnonocccnonaccccnconococoniccnnos 36 10 1 Alender inyore e e e ERMEYE YF 36 10 2 BIS ITS R GNER Processor BSP 500 1200 EF Y Oe AY 36 10 5 COMMING OTOL Module ACON 272 HF O HR RR WR A e 36 T1 WIRING EXAMPLES Lu ie emma dike asia lame ODd GNAU dan i e dias 37 11 1 VOOR O E EEA EAEE NEEE AEA EAE uence E EE E 37 11 2 Comments on the wiring examples cccccccccccsssssscccssssssssseeeccscccccsesseeecccsssssscssesseseccsssssseeeeeesees O7 11 3 VarioTrack Xtender RCC 02 BSP BTS Olhybrid system 38 12 MAINTENANCE OF THE INSTALLATION ccsccccssscccescccssscecssscccsscccessccceesscccsscesessceeescceeescceeescs 39 TS PRODUCT REC VC IN dia NOD aU dead ea la aa sa de amm sai ele ia 39 14 EC DECLARATION OF CONFORMITY scccsssscccssscccsscccssscccssscecesscecsscceeescccesscceeessceeessceeescceeesces 39 15 PARAMETER LISI ak nada a radican 40 16 TEC
34. erature sensor is optionally available to correct the battery voltage and guarantee an optimum charge for whatever battery temperature The correction factor given by the temperature sensor is set by parameter 10036 Reference no for the temperature sensor including a 3m cable BTS 01 Dimensions HxLxl 58x51 5 x 22mm 9 2 1 Connecting the temperature sensor BTS 01 The optional temperature sensor BTS 01 is supplied with a 3m cable fitted with RJ11 6 type plugs It may be connected or disconnected at any time even when the device is operating using the corresponding socket 6 marked Temp Sens on the Variolrack Plug the connector into the socket 6 until it clicks in The temperature sensor case may simply be stuck onto the battery or directly next to it The temperature sensor is automatically recognised and the correction applied immediately lf a BSP battery probe next to the battery is used a BTS Ol is not necessary The BSP module is fitted with a temperature sensor If both elements BTS 01 and BSP are present only the BTS Ol is taken into account to correct the temperatures Temp 9 3 EXTERNAL COOLING FAN ECF 01 The cooling fan ECF 01 is an accessory that can be added to model VT 65 this will give it the features of model VT 80 see technical data p 41 This accessory is automatically detected and the limit of the charging current is 80A when installed This fan has a degree of protection IP54 and can be
35. erminals Accidental presence of liquids in the equipment or oxidation due to condensation Damage resulting from falls or mechanical shocks Modifications carried out without the explicit authorisation of Samlex Nuts or screws that have not been tightened sufficiently during the installation or maintenance Damage due to atmospheric surge voltage lightning Damage due to inappropriate transportation or packaging Disappearance of original identification marks Never take off or damage the rating plate showing the serial number lt enables to check and follow up the data specific to each equipment and is vital for any warranty claim 2 4 2 Exclusion of liability The installation commissioning use maintenance and servicing of the VarioTrack cannot be subject of monitoring by Samlex Therefore we disclaim all responsibility and liability for damage costs or losses resulting from an installation that does not comply with the instructions a faulty operation or inadequate maintenance The use of Samlex equipment is in any case under the responsibility of the customer This equipment is neither designed nor guaranteed to supply installations used for vital medical care nor any other critical installation entailing potential risks of important damage to people or to the environment We assume no responsibility for the infringement of patent rights or other third parties rights resulting from the use of the inverter Samlex reserves the
36. exposed to water spray without damage However do not expose it to dirty water splashes in order to prevent mud or similar particles from blocking the mechanism The assembly instructions are supplied with the accessory Manuel utilisateur V1 0 02 39 Samlex VarioTrack 10 EQUIPMENTS COMPATIBLE WITH THE VARIOTRACKS When making hybrid energy systems Variolracks are often combined with the Xtender mentioned hereunder They belong then to a system where they are interconnected via the communication bus The full description of this equipment is available on our website www studer innotec com 10 1 XTENDER INVERTERS CHARGERS The VarioTrack is compatible with all Xtender and it allows making PV generator or PV network hybrid systems that are perfectly coherent when the communication between the Xtender s and the VarioTrack s allows synchronizing the charging cycles of both pieces of equipment When the function is activated using parameter 10037 the Xtender is the master of the charge profile and will impose the voltage limits set by its cycle It will remain so even if the equipment Xtender is turned off using the ON OFF button On the other hand if the Xtender is turned off using the main ON OFF button de energized the VarioTrack operates with the programmed values The charging current of the equipment add up with no priority When the Xtender charging current is for example set to 100A and the VarioTrack supplies 80A t
37. f the maximum currents mentioned in chap 4 3 3 1 are respected the PV generator can be over dimensioned in order to get the required charging power even when solar irradiation is lower In this case a part of the energy will be lost when the solar irradiation is higher Note the VarioTrack has a current limit The maximum power of the VarioTrack depends on the charging phase voltage of the battery 4 3 3 1 Maximum current of the solar generator The maximum current of the solar generator sum of the short circuit currents for all the strings connected in parallel is 60A for model VT 65 and 75A for model VT 80 Note the National Electrical Code NEC in force in the United States requires a limit of the solar generator current lt 0 8 x rated current of the solar regulator Thus in order to comply with NEC the maximum current for the solar generator is 52A for the VarioTrack model VT 65 and 64A for model VT 80 In any case the VarioTrack will limit the charging current battery to its rated current i e 65A for model VT 65 and 80A for model VT 80 4 3 4 Safe use of the photovoltaic modules The Variolrack is meant for PV generators supplying up to 150Vdc This voltage is dangerous to man During the installation or the maintenance of the system it is mperative to make sure that no dangerous voltage may surge in the system The disconnection device must be open and secured against any accidental reclosing 4 3 5 Protect
38. ge cycle is kepi in floating phase 8 3 9 1 Forcing a new cycle 10029 signal This signal enables to force manually a complete charge cycle The Variolrack switches immediately to the bulk phase 8 3 9 2 Conditions for a new cycle A new battery cycle will be triggered if one or the other 2 conditions defined by a period of time during which the battery voltage is lower than a threshold is met These 2 voltages related to 2 durations are configurable Usually a higher voltage is used for a longer duration and a lower voltage for a shorter duration Voltage 1 for a new cycle 10030 2 03V element Undervoltage duration 1 for a new cycle 100311 30min Voltage 1 for a new cycle 10030 12 2V 24 4V 48 8V Duration under voltage 1 for a new cycle 10033 5sec Voltage 2 for a new cycle 10032 11 8V 23 6V 47 2V Duration under voltage 2 for a new cycle 10033 5sec The battery voltage under which a new cycle is started can be specified The battery voltage must remain under this threshold during a period of time that must be established as well 30 V1 0 02 User manual Samlex VarioTrack 8 3 9 3 Maximum limit of the cycle repetition 10034 Yes The repetition of the charge cycles can be limited establishing the minimum time between each cycle using parameter 10035 8 3 9 4 Minimum interval between cycles 10035 Th Determines the minimum interval time between each cycle when parameter 10034 activates this functi
39. gized in order to interconnect the units on the communication bus 5 POWER UP OF THE EQUIPMENT It is mperative that the closing cover for the connection compartment is installed and screwed tight before energizing the installation There are dangerous voltages inside the cable compartment The connection of the VarioTrack must be carried out in the following order Any disassembly shall be carried out in the reverse order Before closing the protections and energizing the eguipmeni check the polarity A Connecting the battery on the BAT and BAT terminals o Check that the VarioTrack switches on o _ lf there is an RCC 02 03 during commissioning check that the battery voltage is displayed correctly check that the type of installation is correctly recognized 12 24 48V B Connecting the photovoltaic panels on the PV and PV terminals o Check the PV voltage seen on the RCC 18 V1 0 02 User manuol Samlex VarioTrack o Check the operation of the charger and the effective charging of the batteries when if is sunny Your installation is now in operation If the system reguires specific configurations or settings carry them out immediately Settings must be programmed by means of the remote control RCC 02 03 as per chap 8 2 or by means of the internal DIP switches as per chap 8 1 If the equipment seems to have an incorrect behaviour the table hereunder shows some wiring errors and the symptoms related to them
40. h specific manufacturer It covers the following models and accessories Charger VarioTrack VT 65 VarioTrack VT 80 Temperature sensor BTS 01 Cooling fan ECF 01 Note The VarioTrack solar charger has a different specification dependent upon whether it is equipped with a cooling fan model supplied under reference VT 80 or not model supplied under reference VT 63 It is also possible to add the ECF O1 cooling fan on a VT 65 model later see chap 9 3 If the fan is added the specification will become that of a VT 80 This manual is an integral part of the equipment and must be kept available for the operator and or the installer If must remain near the installation so that it may be consulted at any time Manuel utilisateur V1 0 02 5 Samlex VarioTrack 2 2 IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety instructions Read carefully the safety and operation instructions before using the VarioTrack Take into consideration all the warnings mentioned both on the equipment and in this manual following all the instructions regarding the operation and use For clarity s sake in this manual the equipment is called VarioTrack unit or equipment when the operation description applies either to the VT 65 or VT 80 model This user manual is intended to serve as a guideline for the safe and efficient use of the Variolrack Anyone who installs or uses a VarioTrack can completely rely on this user manual and is boun
41. he installation with a clear display interface Moreover it allows recording the system data in order to analyse later its functioning data logging The parallel operation of several chargers is possible and offers modularity and flexibility enabling an optimum dimensioning of your system according to your energy requirements The VarioTrack operates as independent equipment but is also designed to be included into a Samlex energy system together with the Xtender inverters chargers the BSP battery monitor the remote control and programming unit REC 02 03 and the communication module Xcom 2321 Working together this different equipment has a synchronised behaviour for a better management of the battery and of the solar resource To ensure that your system starts up and operates perfectly please read this manual carefully It contains all the necessary information regarding the operation of the VarioTrack charger The installation of such a system requires special expertise and may only be carried out by qualified personnel familiar with the local standards in force 2 GENERAL INFORMATION 2 1 ABOUT THIS USER MANUAL This manual contains all the necessary information and procedures to install configure use and troubleshoot the VarioTrack charge regulators If does not contain information about photovoltaic modules PV or batteries of various brands that can be connected For this kind of information please refer to the instructions of eac
42. he battery charging current may be 180A during the bulk phase 10 2 BATTERY STATUS PROCESSOR BSP 500 1200 This module supplied with a 500 or 1200A shunt allows measuring the current voltage and temperature of the battery lt calculates and supplies the system with all the information obtained from these measures such as the state of charge time before discharge history of the state of charge over 5 days etc 10 3 COMMUNICATION MODULE XCOM 2321 This isolated RS232 module allows accessing most of the values and parameters of the equipment connected to the communication bus It also features an SD card for the acquisition of measured data setting and history of the event generated by the equipment 36 V1 0 02 User manual Samlex VarioTrack 11 WIRING EXAMPLES 11 1 VARIOTRACK RCC 02 yagi u lt ilg i Y m OE Bi 2 je E oF C i Qj NR gt A bolo L L 11 2 COMMENTS ON THE WIRING EXAMPLES Refer to a Remote control See chap 9 1 8 2 and 0 b Battery See chap 4 4 c__ Photovoltaic generator_______ See chap 4 3 d Lightning protection device See chap 4 7 e Communication cable _ See chap 4 8 f DC protection device See chap 4 4 4 C k See chap 10 1 T Protective earth Main protective earth protective equipotential bonding connected to the conductive and accessible parts of the building and if possible
43. he installer The use of the Variolrack connected to any other type of DC source without battery buffer is strictly forbidden and may cause significant damage to the equipment and or to the source 4 4 1 Dimensioning the battery The battery bank is dimensioned depending on the users daily power consumption and the number of days of autonomy required It is dimensioned in order to reduce the daily discharge depth as well In any case the battery bank must be dimensioned in order to reach a reasonable ratio between the maximum charging current and the battery capacity As for lead acid batteries the charging current should be between 0 1 and 0 2 x Cbatt Ah C10 in order to ensure an optimum charge For a 65A charger a battery of at least between 350 and 00Ah is necessary The dimensioning of the battery must also take into account the power and the type of charge that are connected most often an inverter For this type of charge the minimum capacity of the battery bank in Ah may be calculated this way five times the inverter rated power divided by the battery voltage For example an Xtender XTH 8000 48 inverter charger should have a battery capacity of a minimum 7000 5 48 730 Ah C 10 Due to the extreme overload capacity of the inverter it is often recommended that this value be rounded up An under dimensioned battery may lead to an accidental and undesired stopping of the inverter in case of high demand This stopping is due
44. hey can thus be installed outdoor or in an environment exposed to dust or splashes However do not expose the VarioTrack under direct solar radiation or near a heat source The presence of a heat source may reduce significantly its rated power Similarly insufficient ventilation may lead to the overheating of some internal components of the equipment In this case the device will automatically limit its power as long as this abnormal situation persists As far as possible reduce exposure to sudden temperature variation important heat variation may create undesired and harmful condensation inside the equipment The VarioTrack is electronically protected against overloads short circuits overheating polarity reversal of the battery polarity reversal of the PV connexion of the panels to the battery input and connexion of the batteries to the PV input 3 4 FIXING DIMENSIONS The VarioTrack is a heavy equipment 5kg and must be mounted to a support wall designed to bear such a load It is imperative to ensure a complete and safe fastening of the equipment If simply hung it may fall down and cause severe damages The VarioTrack must be installed vertically A distance of at least 5cm between the units and or 20cm around the equipment is required to guarantee adequate ventilation If the Variolrack is installed in a closed cabinet it must have a sufficient ventilation to guarantee that the ambient temperature is kept within the oper
45. ifies a parameter not included in the list advanced parameters the number of the modified parameter s the specifications of the parameter s and the new value set are to be indicated at the end of the table All the values that are not followed by a parameter number may not be modified All digits and letters indicated in brackets or in square brackets refer to items that can be found in the figures surrounded with a circle 2 4 QUALITY AND WARRANTY During the production and assembly of the VarioTrack each unit undergoes several checks and tests which strictly comply with established procedures The manufacturing assembling and testing of each VarioTrack are completely carried out in our factory in Sion CH The warranty for this equipment depends upon the strict application of the instructions in this manual The VarioTrack charge regulator has a FIVE 5 years warranty starting from the date of production against material and manufacturing faults The defective product will be either repaired or replaced at the discretion of Samlex 2 4 1 Exclusion of warranty No warranty claims will be accepted for damages resulting from handling use or treatment that are not explicitly mentioned in this manual In particular damages arising from the following causes are excluded from the warranty 6 V1 0 02 User manual Samlex VarioTrack Voltage higher than 150V across PV or battery terminals Battery reversed polarity across PV input t
46. ion battery cycle with Xtender Basic 10005 Floating voltage Basic 10009 Absorption voltage Basic 10017 Equalization allowed Basic 10021 Equalization voltage Basic 10056 Restore default settings MENU 10003 BATTERY MANAGEMENT AND CYCLE see Chap 8 3 5 Basic 10037 Synchronisation battery cycle with Xtender Expert 10002 Battery charge current Expert 10036 Temperature compensation Menu 10004 Floating phase Basic 10005 Floating voltage Expert 10006 Force phase of floating Menu 10007 Absorption phase Expert 10008 Absorption phase allowed Basic 10009 Absorption voltage Expert 10010 Force absorption phase Expert 10011 Absorption duration Expert 10012 End of absorption triggered by the current Expert 10013 Current threshold to end absorption phase Menu 10016 Equalization phase Basic 10017 Equalization allowed Expert 10018 Force equalization Basic 10021 Equalization voltage Expert 10020 Equalization current Expert 10022 Equalization duration Expert 10052 Equalization with fixed interval Expert 10025 Days between equalizations Expert 10026 End of egualization triggered by the current Expert 10027 Current threshold to end equalization phase Experi 10019 Equalization before absorption phase Menu 10028 New cycle Expert 10029 Force a new cycle Expert 10030 Voltage level 1 to start a new cycle Expert 10031 Time period under voltage level to start a new cycle Expert 10032 Voltage level 2 to start a new cycle Expert 10033 Time period under voltage level 2
47. ion devices Wiring protection devices fuses circuit breakers connecting the PV generator to the VarioTrack must be installed according to the standards The DIN VDE 0100 712 standard prescribes a switching device on all poles between the PV generator and the charge regulator This device must be supplied by the installer PV modules are often very exposed to storm weather It is highly recommended to install lightning protection see chap 4 7 4 3 6 Cable cross section The connection cable cross section must be chosen according to the short circuit current of the PV generator and the local installation rules A 295mm cross section is recommended Terminals M6 must be tightened at a torque of 5 Nm All connection cables as well as the PV cables must be mounted using cable restraints in order to avoid any traction on the connection 4 3 7 Parallel connection of several VarioTracks As much as necessary VarioTrack could be connected in parallel on the same battery bank according to the battery capacity Each will have its own independent solar generator and is connected with its own disconnecting and protective device to the battery Up to 15 VarioTrack could be synchronized and interconnected to the same communication bus see chap 4 8 on a single system Beyond these 15 units any additional unit will not be interconnected and thus their battery cycles will work independently When the VarioTrack are not synchronized they must be p
48. ld be available for this purpose Particular care is required when working close to the batteries with metal tools Tools such as screwdrivers open ended spanners etc may cause short circuits Sparks created by short circuits may cause the battery to explode When working with the batteries all metal jewellery such as rings watches with a metal bracelet earrings etc must be taken off The current supplied by the batteries during a short circuit is sufficiently powerful to melt the metal and cause severe burns Always follow carefully the instructions of the battery manufacturer If the battery voltage exceeds the value of 17 34 68V the charger turns off and starts again when the voltage is lower than 16 32 64V A battery voltage higher than 20 40 80V can cause an important damage or destroy the equipment Such a voltage applied on equipment connected downstream like Xtender inverters chargers or else can cause an important damage or destroy these equipment 4 4 3 Connecting the battery All connection cables as well as the battery cables must be mounted using cable restraints in order to avoid any traction on the connection Battery cables must also be as short as possible and the cross section must comply with the regulations and standards in force Tighten the clamps on the Battery inputs sufficiently Each Variolrack is connected directly to the battery using its own protective device All other consumers or sources
49. less than 1W The charger automatically switches on again when sun starts shining and PV voltage goes back above the battery voltage 6 3 u CHARGE CYCLE INDICATOR 2 This yellow indicator lights up when the sun is shining and the photovoltaic generator produces enough voltage tor charging the batteries Various flashing modes enable to distinguish in what phase the regulator is This indicator lights uo continuously during the bulk phase It flashes 1x during the floating phase 2x during the absorption phase and 3x during the equalization phase In synchronized mode the cycle state floating absorption equalization is not indicated Only the charge LED 2 and the indicator for the amount of charge are used when the equipment is operating 20 V1 0 02 User manual Samlex VarioTrack 6 4 ERROR INDICATOR 3 The table hereunder describes the type of error according to the number of times this indicator flashes Indic Off No problem If no indicator lights up the equipment Is de energized On The equipment is OFF The equipment is energized but it does not operate because of a user command the Set button has been pressed for 5s Flashes The eauipmen is still operating but shows that the 1x warming battery is lower than 10 20 40V Flashes Earth fault The VarioTrack detects an abnormal situation which does not correspond to the programmed value of the parameter 10060 checking the state of the earth
50. manual Open equalization 54 4V 57 6V 2h 63 2 V manual Open reduced voltage 53 6V 57 2V 2h 63 2 V 1 20 days manual DIP switches no 5 and 6 do not have a dedicated functionality spare DIP switches no 7 and 8 allow setting the battery voltage 24 V 1 0 02 User manual Samlex VarioTrack The automatic mode measures the battery voltage upon connection of the equipment and sets the system rated voltage f Voatt lt 17v gt 12V system f IV lt Vpatt lt 34V 2 24V system If 34V lt Vbatt gt 48V system This automatic detection is correct in most cases But the connection of a very discharged battery may lead to an error in the automatic voltage selection For example the connection of a highly discharged 24V 16V battery will select automatically a voltage of 12V which prevents to recharge the battery This is the reason why if is advisable to set manually the system voltage either using the DIP switches see table above either using the RCC remote control Settings defined by the position of the DIP switches may be inhibited disabled with parameter 10054 using the remote control RCC 02 03 The VarioTrack operation will then be defined only by the parameter values set by default or by the RCC remote control When several Variolracks interconnected communication to the same battery are used differences in production power are normal especially in the following cases The units are in voltage regulati
51. may be freely modified in order to get a charge profile that meets at best the reguiremenis set by the manufacturer or the user If the BTS 01 temperature sensor is used the voltage regulation thresholds of the battery are corrected in real time according to the battery temperature The value of this correction in mV C cell for a reference temperature of 25 C is set by parameter 10036 to 3mV C cell For example at 30 C for a 24V battery having thus 12 cells of 2V 80 25 12 4 1000 0 24V a floating set to 27 2V is compensated to a value of 26 96V Manuel utilisateur V1 0 02 27 Samlex VarioTrack The battery setting is carried out under the responsibility of the operator An incorrect setting that does not meet the battery charging methods recommended by the manufacturer may be dangerous and or considerably reduce the battery service life If the factory settings are modified the new values must be entered in the parameter table at the end of this manual 8 3 5 1 Synchronization of a battery cycle with an Xtender 10037 yes This parameter appears on the basic menu and is described in chap 8 3 4 2 au dessus When this parameter 10037 is activated all other parameter involved in the battery cycle are hidden and not accessible In this case only the maximum charging current is adjustable If an Xtender inverter charger is interconnected communication to a VarioTrack the Xtender battery cycle will be imposed to the Va
52. mox 15 units via a communication bus see chap 4 8 that uses the connectors 7 and a cable ref CAB RJ45 2 that is max 5 metres long When both connectors 7 are used the termination selector 8 must be in O open position Im multi unit systems the charge is synchronized up to 15 units and the battery bank is common Each VarioTrack will be independently connected to his own solar generator without any connection to the other PV generator connected to other VarioTrack When they are interconnected by means of the communication cable the VarioTracks synchronize automatically in order to get a cohereni battery cycle When the equipment is in the voltage regulation phase their current may considerably differ These differences have no effect at all on the charge quality During the commissioning of the equipment in a multi unit configuration the system checks automatically the compatibility of the software versions and may prevent the operation in case of incompatibility An upgrade of the installation must then be carried out by means of the RCC 02 03 remote control using the latest manufacturer s software version read the user manual for the remote control and programming unit REC 02 03 to carry out this operation 4 5 1 Extension of an existing installation In interconnected installations if the software is compatible it is possible to extend an existing installation by adding one or several up to 15 VarioTracks in p
53. n of electrolyte a premature ageing or destruction of the battery Follow scrupulously the instructions and recommendations of your battery supplier Caution incorrect values which do not comply to the manufacturer s instructions can lead to a premature ageing and even the destruction of the batteries For more information contact your battery supplier who will inform you on the values to be applied for his products 7 2 5 Temperature compensation If a BTS 01 or BSP temperature sensor is used the voltage adjustment thresholds for the battery are corrected in real time according to the battery temperature The value of this correction in mV C cell for a reference temperature of 25 C is set by parameter 10036 to 4mV C cell For example for a 24V battery 12 cells of 2V at a temperature of 30 C we shall get 80 25 12 4 1000 0 24V For a floating voltage value 10005 set to 27 2V the effective floating voltage compensated will be 26 96V Before opening the VarioTrack it is absolutely mandatory to disconnect all DC sources battery and PV from the equipment to avoid any danger Before opening the equipment let the internal filtering capacitors to discharge 7 3 DEFAULT BATTERY CHARGE CYCLE ORIGINAL SETTINGS The charge cycle set by default does not allow the equalization phase and carries out only phase bulk 2 absorption and 4 floating as per figure hereafter These factory parameter values of the Va
54. on If this function 100034 is activated and the interval parameter 100035 is set to 24h there will be only one charge cycle per day In this case if the conditions are met for a new cycle it will not take place and the charger will keep the battery at floating voltage 8 3 9 5 Correction coefficient for battery temperature 10043 3mV C cell If a battery temperature sensor BTS 01 is used in the system the charging voltages are automatically adapted to the battery temperature The compensation is given in millivolts per degree Celsius C and per battery cell For example at 30 C for a 24V battery having thus 12 cells Of 2V 30 25 12 4 1000 0 24V a floating set to 27 2V is compensated to a value of 26 96V 8 3 9 6 Battery charging current 10002 65 80A depending on model The Variolrack tries to maximize the battery charging current up to its rated current however it Is possible to limit this current using this parameter for small capacity batteries The current appropriate to the battery is reported in its technical data The value set by this parameter is used during the whole bulk phase If no information on the charging current is available the most frequently used value is of one fifth of the battery capacity Ex for 500Ah 500 5 100A Caution if your batteries are in series to calculate the capacity only one has to be taken into account and not the sum If the battery bank is composed of several s
55. on phase absorption egualization floating and in this case the current distribution may be very uneven This situation is normal and has no influence on the system efficiency The eguipmeni are in a bulk phase in this case the difference is due to the difference in size orientation cleanness shade or any other situation that may influence the production capacity of the solar generator This situation may require the generator to be checked in order to clear remedy the possible fault 8 2 CONFIGURING THE VARIOTRACK USING THE REMOTE CONTROL RCC 02 03 Many parameters are stored in the VarioTrack internal memory When a parameter is modified using the remote control RCC 02 03 hereafter referred to as RCC it is sent to the VarioTrack and stored permanently If the RCC is removed from the system this parameter continues to be used by the VarioTrack with this modified value If the VarioTrack is de energized and then energized again the new value can be retrieved from the memory This allows for example to pre program a VarioTrack at the workshop and to supply it to a customer ready for his specific application If the settings made using the DIP switches are disabled either because the Pos 1 off or because the parameter disabling the DIP switches 10054 yes the Variolrack uses its stored values The factory parameter values of the equipment are equivalent to the values set when all the DIP switches are in OFF position i e adapted
56. on the rating plate positive pole Input protection fuse Fuse 4 x 30A 80V See sect 4 4 4 1 Socket for BTS 01 battery temperature Only the mentioned original accessories can sensor and ARM 02 auxiliary relay be connected to this connector See chap 9 module accessories Socket for communication cables RJ45 connector used for connecting equipment of the Xtender family These connections must be carried out only with original Samlex cables Termination switch The switch must be placed in position O towards 9 when both connectors 7 are used configuration switches The various possible configurations are described in chap 8 1 Real time clock battery The eauipment is fitted with a battery lasting type CR 2032 about 10 years V 1 0 02 User manuol Samlex VarioTrack 4 2 CONNECTION COMPARTMENT gt A HAY Ha LL _F ss ce Manuel utilisateur V 1 0 02 1 Samlex VarioTrack 4 3 PHOTOVOLTAIC GENERATOR PV The VarioTrack may accept input voltages between O to 150V max lts operating range as a charger starts from a value above the battery voltage up to 145V If the no load voltage of the panel is above 75V in all the temperature range the whole solar system must be installed according to class of protection ll 4 3 1 Dimensioning The solar generator Is dimensioned to cover an important part or the entire power reguiremeni of the system Once the power has been de
57. oon as this absorption voltage is reached the duration of the phase is counted down as long as the voltage remains higher than the floating phase 10005 If the charging current is lower than 4A 10013 whereas the voltage limit is reached the absorption phase is considered finished The end of the absorption triggered by the current 10012 can be disabled if necessary The absorption phase can be disabled by parameter 10008 The maximum voltage that can be reached will be the floating voltage 10005 It is the case when charging a Li lon battery 7 2 3 Floating phase When the battery is completely charged a constant reduced voltage 10005 is applied on the battery This voltage prevents self discharge and keeps the battery at its maximum charge level and reduces to the minimum the water evaporation that would occur at a higher voltage 7 2 4 Equalization phase This phase is allowed 10017 only for open batteries with liquid electrolyte During this phase the set voltage limit for the battery is temporarily 10022 higher It allows on one hand to equalize the electrolyte density through mixing corrosion control and on the other hand to equalize the charge among the cells of the battery During this phase the charging current can be limited by parameter 10020 When authorized this battery maintenance phase is carried out at fixed intervals 10052 before the absorption phase This increase in voltage may be applied after the absorp
58. rack model VT 65 and 64A for model VT 80 2 The generator power depends on various elements as well as on the voltage and power limits recommended in chapter 4 3 1 16 2 Oureur BATTERY Battery rated voltage 12V 24V 48V automatic or manual setting Battery input voltage range 68V Max charging current of the battery at 25 409C 65 60A 80 75A Night mode consumption 12V 24V 48V 0 5W 0 8W 1 2W Charging phases adjustable threshold and Periodic or manual bulk absorption floating duration equalization Battery temperature compensation 3mV 9C cel ref at 25 C 16 3 ENVIRONMENT EMC directive 2004 108 EC IEC EN 61000 6 3 2011 IEC EN 61000 6 1 2005 EC Conformity Low voltage directive 2006 95 CE IEC EN 62109 1 2010 ROHS directive 2002 95 EC SAMLEX proprietary bus and protocol Remote control and programming unit Communication RCC 02 03 Isolated RS 232 with Xcom 232 i accessory 16 4 ELECTRONIC PROTECTION Overtemperature Max 70 C gt power reduction stop Manuel utilisateur V1 0 02 A Samlex VarioTrack 17 NOTES A2 V1 0 02 User manuol Samlex VarioTrack Manuel utilisateur V 1 0 02 43 SA MIL E X EUROPE B V www samlex com www samlex solar com
59. rioTrack 8 4 DISPLAYING THE EQUIPMENT STATUS USING THE REMOTE CONTROL RCC 02 03 8 4 1 Displaying the status of a simple unit system The VarioTrack screen allows displaying in real time 4 values to be chosen among many measured or calculated values reported in the table hereunder Hi 99 2 de The SET key allows entering the first field that appears in reverse riode _ Charger video To modify the field content use the SET key then using the Phas __ Bulk u arrows consult the various displayable values and select them as permanently displayable values in the related field by validating with the SET key When no other value than the one initially displayed in the field is selected ESC key validates the initial choice The 4 fields can be successively scrolled and modified any time in order to display the values of 4 pieces of information chosen from the table hereunder Info no Name Unit Description Battery voltage Battery current Voltage of the PV generator Power of the PV generator Battery temperature when sensor available Production in Ah for the current day 11038 phas Text Battery cycle phase Bulk Absorption Equalization Floating XT slave MPPT slave 8 4 2 Displaying the operating mode of the equipment Charger the charger operates normally at the maximum power point of the solar generator or in voltage regulation Night the solar generator voltage or luminous intensity is not enough to star
60. rioTrack are adapted to open lead acid batteries with no equalization with an absorption voltage of 14 4 28 8 57 6V for 2h and a floating voltage of 13 6 27 2 54 4V equivalent to the off position of t h the DIP switches n 2 3 and 4 when the Variolrack is configured using the internal DIP switch bank Manuel utilisateur V 1 0 02 23 Samlex VarioTrack 8 CONFIGURING THE VARIOTRACK S The Variolrack can be configured simply allowing charge behaviours that meet perfectly the requirements of most lead acid batteries This configuration can be carried out using the DIP switches 9 inside of the eguipmeni to set the various configurations according to the position of each DIP switch If an Xtender inverter charger is interconnected communication to a VarioTrack the Xtender battery cycle will be imposed to the VarioTrack of the system This function may be disabled by parameter 10037 If no Xtender is connected to the VarioTrack the latter uses ifs own setting It is also possible to make configurations specific to particular requirements of the system thanks to the remote control RCC 02 03 described in the following chapter 8 1 CONFIGURING THE EQUIPMENT BY MEANS OF THE INTERNAL D P SWITCHES The DIP switch no 1 first on the left allows activating the settings defined by the DIP switch bank This activation will not be taken into account if the parameter 10054 does not allow it When the settings defined by the DIP
61. rioTrack of the system This function may be disabled by parameter 10037 If no Xtender is connected to the VarioTrack the latter uses its own setting 8 3 6 Floating phase 10004 menu 8 3 6 1 Floating voltage 10005 13 6V 27 2V 54 4V Determines the voltage applied when the battery is fully charged This voltage prevenis self discharge and keeps the battery to its optimum charge level 8 3 62 Force floating phase 10006 signal This parameter may be used to force a battery cycle in progress to assume the final values of the floating voltage phase If the battery voltage level is higher the charger momentarily switches out until the new target voltage is reached 8 3 7 Absorption phase 10007 menu During this phase the battery accumulates the last percentages of power to be stored This phase takes place at a constant voltage 8 3 7 1 Absorption phase allowed 10008 yes This parameter determines whether the absorption phase is carried out or not When this phase is disabled the charger goes directly to the following authorized phase equalization but most often a floating phase 8 3 7 2 Absorption voltage 10009 14 4V 28 8V 57 6V Define the applied voltage during absorption phase 8 3 7 3 Force absorption phase 10010 signal This signal starts again an absorption phase from the floating phase The charge indicator 2 flashes 2x indicating that the equalization phase is on going 8 3 7 4 Absorption dur
62. rogrammed in a same way and it s recommended to not activate the periodical equalization function The equalization can be manually started or will be done by the synchronized units Solar generators may be of various types and be orientated differently Each VarioTrack will adjust the optimum point of the PV generator independently of the other units connected to the same battery Manuel utilisateur V 1 0 02 13 Samlex VarioTrack PV generators can in no circumstance be connected together in whatever manner before the VarioTrack Im multi unit systems all the VarioTracks of a same system must be connected to the same battery bank Im multi unit systems each Variolrack is connected to the common battery using Its own protection device All other consumers or sources are connected directly to the battery using their own protection device 4 4 CONNECTING THE BATTERY The Variolrack is a device which DC battery connection is to be connected exclusively to a battery Most of the time lead acid batteries with liquid VLA VRLA or gelled GEL and AGM electrolyte may be used It can be easily configured to create charge profiles that are compatible with these various types of lead acid batteries The use of other battery types like Ni Cd Li ion or other is possible if the charge profile is properly programmed in accordance with the specifications of the battery manufacturer in agreement with him and under the responsibility of t
63. sed only to connect a compatible Xtender accessory excluding any other type of connection such as LAN Ethernet ISDN etc The remote control and programming unit RCC 02 03 is compatible with the following equipment Variotrack solar charge controller MPPT Xtender inverters chargers When it is connected to at least one of these two devices if also allows interacting with the other peripherals of an Xtender system i e Battery measuring system BSP 500 BS 1 200 RS 232 communication interface Xcorm e 3i TRISTAR communication interface Xcam MS It allows the following functionalities for all the connected and compatible equipment e Setting the various operating parameters for the connected equipment e Displaying the operating synoptic for each piece of equipment e Displaying several operating quantities measured or calculated Current Voltage Power etc for each apparatus e Updating the software or implementing tailored software e Backing up restoring system parameters configuration e Loading a parameter file configuration e Storing error message history for each equipment e Recording VarioTrack s data and other information essential for the system see chapter Data recorder p 23 in the RCC manual RCC 02 7 y oS Aa obia M ee e i 2 4A OFF 8 mb Li 21 7 yd LI Functionalities of the RCC 02 and RCC 03 units are equivalent They differ only in their external aspect The RCC O2 is designed for
64. switch bank are not activated the default parameters see list p 40 are applied These parameters can be modified by means of the remote control RCC 02 03 If the default parameters factory parameters are modified the new values must be reported in the parameter table p 40 at the end of the manual which must remain on the installation site at the disposal of the maintenance personnel When the VarioTrack is connected to other VarioTracks via the communication bus the settings of the DIP switches must be the same for all the interconnected Variolracks The charge cycle is automatically synchronized and will be equivalent on all units When the Variolrack is connected to Xtender inverter s the battery cycle is automatically synchronized with the cycle and the values chosen by the Xtender This synchronization is disabled by parameter 10037 Function DIP switches not taken into account default parameter or set by the remote control ROC 02 03 ON DIP switches taken into account or synchronized by the Xtender if activated 10037 and allowed 10054 DIP switches no 2 3 and 4 allow the battery cycle to be modified as per table hereunder in order to adapt it to the various types of most common lead acid batteries The following values are for a 48V system and must be divided by 2 or 4 in the 24V and 12V applications respectively A AAA voltage voltage period Open equalization 5A AV 57 6V 2h 63 2 V 1 20 days
65. t always comply with these standards The cross sections of the cables connected to its terminals must comply with local regulations Make sure that connections are completely tightened and that each wire is connected af the right place The VarioTrack is intended to be connected exclusively to a source like a photovoltaic generator excluding any other energy source It is suitable for charging any type of lead acid batteries It is often possible to charge any other type of battery using proper settings and with the express approval of the battery supplier The connection compartment of the VarioTrack must remain permanently closed while the apparatus is operating Before opening check that all voltage sources battery and PV have been disconnected or switched off and wait for at least 2 minutes before opening the equipment It is mperative to close the protection cover on the connection terminals after each servicing o Terminal to connect the battery negative This connection must be done using a pole protection and disconnection device if the pole has not been earthed Terminal to connect the battery positive This connection must be done using a pole protection and disconnection device if the pole has not been earthed o Terminal to connect the solar generator The solar generator wiring must be carried out negative pole in compliance with the voltage and current Terminal to connect the solar generator limits mentioned
66. t been Charging for more than 48h Check the protection devices the wiring of your solar generator or clear the persistent shade snow Check the PV wiring see chap 4 3 2 Caution A voltage higher than 150V can seriously damage the device Voltage of the PV generator too high LED error 3 flashes 5 times If the VarioTrack has been accidentally connected the wrong way round battery reverse polarity on the panel input it is likely that the protection device on the battery cables is open In such case recheck carefully the battery polarity the wiring correctness and the internal fuse of the Variolrack that protects against this situation If after having closed or replaced the protection device f the VarioTrack still does not work despite the correct polarity and voltage of the battery it must be brought back to the Seller for repair Manuel utilisateur V 1 0 02 Samlex VarioTrack 6 DISPLAY SYSTEM The VarioTrack is fitted with a Set button and light indicators on the front of the equipment allowing a clear identification of the operating mode 6 1 THE SET BUTTON 4 The push button SET can be used to start manually an equalization cycle if this phase is 70 80A authorized by the initial settings of the equipment The equalization phase will be authorized as from the beep after having sor 2x Vario Track MPPT solar charger 50 60A pressed the key Set 4 for 2 seconds The sh
67. t on the generator side either a reverse connection of the battery on the solar input In such case check carefully the operation of the equipment after the error has been corrected The fuse is composed of 4 fuse links 30A 80V that must be replaced by fuses of exactly the same type i e ref Littlefuse FKS 166 7000 530 or equivalent This operation must be carried out by qualified personnel In case of doubt the equipment must be returned to the supplier for a check this fault is not covered by the warraniy 00 gt 6 5 INDICATOR FOR THE AMOUNT OF CHARGE 5 6 7 8 These indicators flash or light up continuously to indicate F Flashing Indicator Lit up the current charging range as per the table hereafter a indicator number indicator 60 70A LED 8 70 80A The RCC 02 03 remote control allows a complete and c display of the VarioTrack behaviour see chap 40 50A LED 7 50 60A 1 20 30A LED 6 30 40A 0 10A LED 5 10 204 Manuel utilisateur V1 0 02 21 Samlex VarioTrack 7 BATTERY CHARGING PROCESS 7 1 GENERAL POINTS The VarioTrack have many parameters that can be modified by the user or the installer in order to adapt the equipment to the energy system the best possible way The factory values of these parameters are reported in the table at the end of this manual These parameters can be modified by means of the remote control RCC 02 03 optional see chap 8 4 1 p 32 and for some of them a basic
68. t the equipment When this indication appears during the day it means a generator fault wiring Startup the solar generator or luminous intensity is not enough to start the equipment but sufficient to produce power This indication appears only in the morning or in the evening Security the equipment turns off due to a fault normally indicated by a message on the RCC or by the error indicator 3 on the equipment Off the equipment is manually turned off by the operator or using a remote control Variolrack A B Ubat 49 5 MER 8 4 3 Fault visualization Info n 11034 Lorsqu une erreur de s curit est signal e l appareil s arr te Un texte raccourci limit 8 caract res apparait pour les erreurs suivantes Description No error The unit is fully functional GroundFD A ground fault is detected depending on to the configuration chap 4 6 1 Alarm 81 An abnormal high temperature is detected Alarm 014 32 V1 0 02 User manual Samlex VarioTrack Description The battery voltage is over 68V Alarm 020 There is a PV voltage over 75V in a 12V system or over 145V in others Alarm 82 NoBatt No Battery or battery bellow 7V or battery polarity reversed Alarm 80 System error 8 4 4 Displaying the values of a multi unit system When several Variofracks are pra HOLTI ariolrae rn connected to the remote control p E MN ee 14 4 vaci RCC 02 03 the screen hereafter Jai Uba t 26 9 Uae
69. tion phase by modifying parameter 10019 By default equalization is foroidden because incompatible with gel or AGM type batteries It may be authorized by parameter 10017 The equalization can also be authorized depending on the setting of the DIP switch inside of the equipment see chap 8 1 22 V 1 0 02 User manual Samlex VarioTrack The battery cycle is suitable by default for a large number of batteries whether gel or not because the equalization phase is not activated When this phase is authorized it can be started manually by pressing for 2 seconds the SET button on the front of the Variolrack The countdown for the equalization time starts as soon as the equalization voltage 10021 is reached and lasts as long as the battery voltage is higher than the absorption voltage 10009 In this case it would be appropriate to set an equalization charging current 10020 to a value different lower from the bulk current Caution the equalization of open batteries vented produces highly explosive gaz The battery room and or compartment must be adequately ventilated Be careful this charging phase may bring the batteries to voltage levels that can damage a sensitive load connected to the battery Check that the connected loads are compatible with the highest voltage levels possible taking into account any compensation of the temperature sensor A too long or frequent equalization phase can lead to an excessive Consumptio
70. to an insufficient voltage of the battery subjected to a strong discharge current Choose the battery according to the greatest value resulting from the calculation suggested above The wiring and connection of the installation must be carried out only by a perfectly qualified personnel The installation material such as cables connectors distribution boxes fuses etc must be appropriate and comply with the laws and regulations in force for the application in question 4 4 2 Precautions when using the batteries Lead acid batteries with liguid or gelled electrolyte produce a highly explosive gas during normal use Avoid source of sparks or fire in the immediate vicinity of the batteries The batteries must be 14 V1 0 02 User manual Samlex VarioTrack kept in a well ventilated place and installed so as to avoid accidental short circuits when connecting Never try to charge frozen batteries When working with batteries a second person is required in order to give assistance in case of problems Sufficient fresh water and soap must be kept close at hand to allow adequate and immediate washing of the skin or eyes affected by accidental contact with the battery acid In the event of accidental contact of the eyes with acid they must be washed carefully with cold water for 15 minutes Then immediately consult a doctor The battery acid can be neutralized among others with yeast in powder A sufficient quantity of yeast in powder shou
71. to start a new cycle 26 V 1 0 02 User manuol Samlex VarioTrack Expert 10034 Cycling restricted Expert 10035 Minimal delay between cycles MENU 10038 SYSTEM see chap 8 3 9 Expert 10054 Block manual programming dip switch Expert 10060 Check Earthing Basic 10056 Restore default settings Expert 10039 ON of the VarioTrack Expert 10040 OFF of the VarioTrack Expert 10051 Reset of all VarioTrack 8 3 4 Basic menu 10000Xmenu 8 3 4 1 System voltage 10001 Automatic The Variolrack can recognize the battery automatically When powered up battery side it measures the existing voltage and detects whether it is a 12V 24V or 48V battery The VarioTrack can be forced to operate with a certain voltage thanks to parameter 10001 When the battery voltage is clearly known it might be useful to set the battery voltage 12V 24V or 48V This may avoid a possible confusion when connecting an extremely discharged battery and may allow to recover such a battery 8 3 4 2 Synchronization of a battery cycle with an Xtender 10037 yes When an inverter of the range Xtender is used in the system it can transfer to the VarioTrack its battery charge setting so that they can operate together in an optimum way Synchronization allows a coherent operation of multiple units which participate to the battery charging and avoids multiple successive equalizations triggered by each charger 8 3 4 3 Battery floating voltage 10005 13 6V 27 2V 54 4V
72. tors RJ45 8 7 see chap 4 1 Elements of the cable compartment that enable to transfer information via a communication bus to other VarioTracks or to other equipment such as RCC or BSP having the proprietary protocol of Samlex see chap 8 4 1 All the units in the network are connected in series strings The termination switch of the communication bus Com Bus 7 remains in position T terminated except when both connectors are used In this case and only in this case the switch must be placed in the O open position If one of the two connectors is not used the termination switch 7 will be in position T The max cumulated length of the communication bus is 300m Due to a line voltage drop it is recommended to install only one REC module at the end of a 300m line or a max of 2 modules at the end of a 150m line All the other modules of the system must be placed within the same radius of a few meters technical room A maximum of 2 RCC 02 03 or Xcom 232i may be connected to the same communication line with a VarioTrack For more information refer to the RCC 02 03 or Xcom 232i manuals available on our website at the following address www samlex com The communication bus will be used to interconnect other Variolrack chargers in the case of a multi unit application or to connect other types of users who have Samlex s proprietary protocol Xtender BSP In these cases the installation must be switched off and de ener
73. trings to calculate the capacity the sum of the capacities of a battery of each string has to be taken into account 8 3 10 System 10038 menu 8 3 10 1 Inhibiting the configuration made by DIP switches 10054 no Enables to cancel the operating mode chosen by means of the DIP switches inside the VarioTrack If Parameter 10054 is set to yes the DIP switches will remain disabled even if the RCC is removed after configuration This secures the configuration of the facility and to prohibit any subsequent changes with the DIP Switches 8 3 10 2 Checking the earthing 10060 no control When the battery negative pole is earthed as per recommendations in chap 4 6 this connection can be checked by the VarioTrack continuously Would this connection be faulty the equipment turns off immediately and a fault is displayed see chap 6 4 or notified by an alarm message on the RCC see chap 8 4 4 1 The various earth connection types that can be checked are the following No check default value The negative pole of the battery is earthed The positive pole of the battery is earthed Floating battery with no earthed poles 8 3 10 3 Restore default setting 10056 signal This signal will restore the initial parameters of the Variolrack If the installer made specific setting at commissioning this function will restore these settings instead of the factory settings Manuel utilisateur V1 0 02 31 Samlex Va

Variotrack VT 65_VT 80

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