Home

VarioTrack MPPT solar charge regulator VarioTrack

1. Contact activated with the temperature of Expert 10178 battery AUX 2 N 10179 Contact activated over AUX 2 A 1 10180 Contact deactivated below AUX 2 10181 med id if the battery is not in bulk phase CI O Contact activated with the SOC 1 of battery Expert 10183 AUX 2 10184 Contact activated below SOC 1 AUX 2 50 SOC MEE 10185 Delay 1 AUX 2 ra O Expert 10186 a activated with the SOC 2 of battery TS Manuel utilisateur V 3 2 0 4 NO Studer Innotec SA VarioTrack User Level Parameter Factory value value 10187 Contact activated below SOC 2 AUX 2 10188 Delay 2 AUX 2 02h O E activated with the SOC 3 of battery BEC 10190 Contact activated below SOC 3 AUX 2 208 Expert 10191 Dely3 AUX2 1 On Expert 10192 Contact deactivated over SOC AUX2 90 SOC 50 V 3 2 0 User manual Studer Innotec SA VarioTrack 17 TECHNICAL DATA VarioTrachk VarioTrachk 17 1 INPUT PV GENERATOR VT 65 VT 80 Peak efficiency gt 99 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 VarioTrack 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 VarioTrack VarioTrachk Var
2. S w 23 PAR BONG IOS mE 23 TA AROS NON NS oa 23 LES TROCITO PROS UN 23 mo a Be roo o a A A A ln 23 E25 Tembe Iure COMPE OT Nuts 24 7 3 Default battery charge cycle original settings ue 25 8 CONFIGURING THE VARIOTRACK S ccccsssccccssssccccsssccccsssscccessscccesssccceessecccesscceessccseesseceeanes 25 8 1 Configuring the equipment by means of the internal DIP swiftches 25 Manuel utilisateur V 3 2 0 3 Studer Innotec SA VarioTrack 8 2 Displaying the equipment status using the remote control RCC 02 03 eese 26 8 2 1 Displaying the status of a single UNITS STE 26 8 2 2 Displaying the operating mode of the equipment INFO n 11016 28 8239 DISPIEYINOa seCUMY eros dno AOS ds 28 8 2 4 Displaying the values of a multi unit SOM 28 8 2 5 Displaying messages and event history ic A ii di 28 8 3 Configuring the VarioTrack using the remote control RCC 02 03 RL 27 A io ag 2510 E AAA A RH 30 8 4 Besciption or The VarioTraek POTTS Sin A an 30 DA CONVO TR T N le oi ue 30 GAZ Poerdmeler iceess ICV a o e e e id 30 O9 XOIgansailemermiececolliguralion MENU ni AAA 30 Sd BASE MENUDO scene tton rte eei e edv 3 8 4 5 Management and battery cycle 10003 menu y 32 G4 6 Hodnoune phdsexo0UAV Tie id ses cos cree he nn 33 Gr cAOSONOMOM pPRase 1 10007 MENU sr 39 8 4 8 Equalization phase 10016 MENU o c ccceccccsssceeccsescsscsccecsecesenc
3. 9 ACCESSORIES 9 1 REMOTE CONTROL AND PROGRAMMING CENTRE RCC 02 03 This accessory is an important complement to the VarioTrack It 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 When the remote control RCC 02 03 is connected to another compatible device Xtender VarioString BSP Xcom or other with the same communication bus it is possible that the software versions are not compatible It is highly recommended to make a software update of all components in the system in order to guarantee all functionalities Therefore before starting the setup of the device download the latest software version from our website www studer innotec com on an SD card Follow the instructions in the RCC manual for a successful installation These connectors must be used only to connect a compatible Xtender accessory excluding any other type of connection such as LAN Ethernet ISDN etc The remote control RCC 02 03 is compatible with the following equipment e WVarioTrack solar charge controller MPPT e VarioString solar charge controller MPPT e Xtender inveriers chargers When it is connected to at least one of these two devices it also allows interacting with the other peripherals of an Xtender system i e e Battery Status Processor BSP 500 BSP 1200 e RS 232 communication interface Xcom 2321 e Internet b
4. The maximum power of the VarioIrack 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 VarioTrack is meant for PV generators supplying up to 150Vdc This voltage is dangerous for human beings During the installation or the maintenance of the system it is imperative 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 Protection devices Wiring protection devices fuses circuit breakers connecting the PV generator to the VarioTrack must be installed in accordance with local standards and regulations in force The DIN VDE 0100 712 standard prescribes a switching device on all poles between the PV generator and the charge
5. 2 6V element 15 6V 31 2V 62 4V This parameter determines the maximum voltage during the equalization phase This voltage is corrected by the temperature compensation factor 10036 if a temperature sensor BTS 01 or BSP is installed in the system 8 4 8 4 Battery equalization current 10020 80A The equalization phase can be carried out with a limited current that can be adjusted 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 equalization is started at the end of the absorption phase 8 4 8 5 Equalization period 10022 30min This parameter 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 paused 8 4 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 specified by the following parameter 10025 8 4 8 7 Days between the equalizations 10025 26 days This parameter determines the number of days in between the equalizations 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
6. 3 4 1 Assembling the cooling fan model VT 80 aia 9 A WIRING onto en aai E Eis vti nt O ic M LUE 10 4 Elements of the cable compar ment issued iae ER RES bdsm Re dr RS 10 4 2 Sega alo meo CIS N eda AR die oies ion lite 1 4 3 PROLOGO eleexei ia elei iT TT 12 A aca Uem 12 43 2 Send eonnecthon dsinmg or PV MOUSSE 12 49 9 Faralelconnection oi Py Module SINO Sian 12 4 3 4 Safe use of the phorovolrdletnuioduless dis 13 Ao RO TECUON AS VIC CS Ns 13 A Ea S as A PR HERES 13 434 Parallel connection of several VaoTracKsas ec e o A Oe es 13 4 4 CONTE CIN MS DAME isa aa 14 AA l sDIRASASIONING tie Dante EO ET ETE 14 4 4 2 Precautions when USING The DOBITelISS dd AA as 15 AAS COMMECTIAG Te DANE siii 15 AAA POT CNO NOS VICES Ol ie ONEN nasa dies 16 4 5 MGMT SC ODDS GODS RS bi Dose Detienen a oases 16 on Mb iaceo olas laca o o mU UR UNES 17 4 6 CUR ome 1810 AA A D NEN 17 A MEE eu nio COMM OU a 18 4 7 CORTANDO Te CUORE c n 18 4 8 CONMECIING Ne CONIMUNCato nica DSi daa dadas 18 5 POWER UP OF THE EQUIPMENT iie aE E AA EE 19 Sl WIR eres a a elitr SAMOIMONMS Fees ie ie cea tee te 20 6 DISPLAY SYSTEM idad 21 6 1 Mis o A Tp En 2 6 2 NIGHT tana y INCISO Uli TU TN 2 6 3 Charge CY Cle NACO 2 saskact t T E 2 6 4 EMO WACIG GIORNO e C M di 22 6 5 Charging curent indicar SO 7 O assets ais iaa 22 7 BAITERY CHARGING PROCE Sia di 23 7 1 HN A LAE E Ut I LM e DIM Un 23 2 BOHOM eve ce T
7. 54 4V 57 6V 2h 63 2 V 1 20 days 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 The automatic mode measures the battery Battery voltage voltage upon connection of the equipment A P anes Soa If Vbatt lt 17V gt 12V system f 17V lt Vbatt lt 34V 24V system If 34V lt Vbatt gt 48V system This automatic detection is correct in most cases But the connection of a much 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 it 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 VarioTracks are interconnected communication and linked to the same battery differences in production power are normal especially in the following cases e The units are in voltage regulation ph
8. Expert Expert Expert Expert Expert Expert Expert Expert Expert Expert Expert Expert Expert Expert Inst Expert Expert Expert Basic Inst Inst Expert Expert Expert 8 4 3 1 User ref 10008 10009 10010 10011 10012 10013 10016 10017 10018 10021 10020 10022 10052 10025 10026 10027 10019 10028 10029 10030 10031 10032 10033 10034 10035 10038 10054 10060 10087 10200 10043 10044 10056 10057 10058 10039 10040 10051 Studer Innotec SA VarioTrack Parameter Absorption phase allowed Absorption voltage Force absorption phase Absorption duration End of absorption triggered by the current Current threshold to end absorption phase Equalization phase Equalization allowed Force equalization Equalization voltage Equalization current Equalization duration Equalization with fixed interval Days between equalizations End of equalization triggered by the current Current threshold to end equalization phase Equalization before absorption phase New cycle Force a new cycle Voltage level 1 to start a new cycle Time period under voltage level 1 to start a new cycle Voltage level 2 to start a new cycle Time period under voltage level 2 to start a new cycle Cycling restricted Minimal delay between cycles SYSTEM Block manual programming dip switch Check Earthing Disabling of the display button Reset PV energy meter Reset solar production counters Reset daily min m
9. In synchronized mode the cycle state bulk floating absorption equalization are indicated Manuel utilisateur V 3 2 0 2l Studer Innotec SA VarioTrack 6 4 ERROR INDICATOR 3 The table hereunder describes the type of error according to the number of times this indicator flashes Indic Indicated error Comment IN Off No problem If no indicator lights up the equipment is de energized On The equioment is OFF The equipment is energized but it does not operate 02 because of a user command the Set button has been pressed for 5s Flashes Battery low voltage The equipment is still operating but shows that the warming battery is lower than 10 20 40V Flashes Earth fault The Variolrack detects an abnormal situation which 04 2X does not correspond to the programmed value of the parameter 10060 checking the state of the earth connection The VarioTrack turns off It automatically starts again when the normal situation is restored Flashes Power reduction or stop This may be due to an excessive ambient temperature due to an excessive exposure of the equipment to a heat source sun or to temperature in the deficient or impeded ventilation equipment Flashes Battery voltage higher Check the cause of this excessive voltage The 4x 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
10. No Expert 10118 Battery voltage 3 AUX1 121 242 4 5Vdc Expert 10119 Deloy 3 AUX 1 1 1 1 mm Expert 10120 Battery voltage to deactivate AUX1 13 5 27 54Vdc Expert 10121 Delay to deactivate AUXI 60 min Expert 10122 Deactivate if battery in floating phase AUX 1 No Contact activated with the temperature of 10125 Contact activated over AUX 1 LE 10126 Contact deactivated below AUX 1 o TT Expert 10127 Only activated if the battery is not in bulk phase NE AUX 1 NES De activated with the SOC 1 of battery 10130 Contact activated below SOC 1 AUX 1 50 SOC 10131 Delay 1 AUX 1 Ve Expert 10132 Tr activated with the SOC 2 of battery NO 10133 Contact activated below SOC 2 AUX 1 805 10134 Delay 2 AUX 1 02h J 10135 TW activated with the SOC 3 of battery EC 48 V 3 2 0 User manual Studer Innotec SA VarioTrack ae a n Level Parameter Factory value value OR EE Mu Expert 10138 Contact deactivated over SOC AUX1 90 S0C Expert 10139 Delaytodeactivate AUX1 o 02h 10140 Deactivate if battery in floating phase AUX 1 No 10141 Reset all settings AUX 1 10143 Operating mode AUX 2 Automatic Combination of the events for the auxiliary Expert 10144 contact AUX 2 Any Function OR mI 10145 VarioTrack is OFF AUX 2 10147 Activated in night mode AUX 2 Exp
11. 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 VarioTrack In a system composed of a single VarioTrack the connection of the RCC 02 or RCC 03 may be done without stopping the equipment 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 temperature 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 5m cable BTS 01 Dimensions HxLx1 58x51 5 x 22mm Manuel utilisateur V 3 2 0 4 Studer Innotec SA VarioTrack 9 2 1 Connecting the temperature sensor BTS 01 The
12. a doctor The battery acid can be neutralized with baking soda among other things A sufficient quantity of baking soda should 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 Therefore these kinds of tools must always have isolated handles and never be placed on top of a battery 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 Batteries at the end of their life cycle should be recycled in accordance with directives from the responsible local authorities or the battery supplier The batteries should never be thrown into fire as they may explode Under no circumstances should you try to take apart or dismount the battery as they contain toxic and polluting materials For ungrounded battery systems always check that they are not inadvertently grounded before starting working on the batteries 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 80V
13. 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 47 must be kept updated in case the parameters are modified by the operator or the installer If an authorised person modifies 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 in the text of this manual refer to items represented in illustrations 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 Varolrack 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 6 V 3 2 0 User manual Studer Innotec SA VarioTrack The VarioTrack charge regulator has a five 5 years warranty starting from the date of production against material and manufacturing faults The detective product will be either repaired or replaced at the discretion of Studer Innotec 2 4 1 Exc
14. can cause important damage or destroy the equipment Such a voltage applied on equipment connected downstream like Xtender inverters chargers or other can cause important damage or destroy the 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 pulling 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 VarioTrack is connected directly to the battery using its own protective device All ofher consumers or sources are connected directly to the battery through their own protective device Manuel utilisateur V 3 2 0 15 Studer Innotec SA VarioTrack 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 VarioTrack 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 parallel connection of battery strings Strictly conform to the manufacturer s instructions of use In multi unit systems connected to the same communication bus all VarioTracks must be connected to the same battery bank 4 4 4 Protection device of the ba
15. max limit of 145V 75V when 07 5X than the set value of the battery is 12V The equipment will stop or won t start max operating limit Flashes No voltage has been The PV generator is probably disconnected Check the detected for 48h protection devices fuse or circuit breaker and or check the wiring As a last resort after making sure that the PV generator is disconnected check the internal fuse 5 Flashes Battery fault Missing battery polarity reversal or voltage lower than 7V Flashes Software incompatibility in The different parts of the system s equipment must have OS Co BEER a multi inverter system the same software version to function properly Proceed with the update following the procedure in manual RCC 02 03 Co NS T If the internal fuse is broken this shows a major error in your wiring most probably either a short circuit 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 may consist of 4 car fuses 30A 80V or be one single blade fuse 100A 80V given the version of the PCB you have These fuses should be should be replaced by fuses of the same type Littlefuse or Pudenz FKS 166 7000 530 or equivalent for the 4 car fuses Pudenz 156 5611 6101 or equivalent for the blade fuse This operation must be carried out by qualified personnel In case of doubt the equip
16. 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 VarioTrack 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 liquid electrolyte batteries vented produces highly explosive gas 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 consumption 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 with 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
17. 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 charging the battery absorption equalization floating are automatically corrected in real time according to the battery temperature The value of this compensation in mV C cell for a reference temperature of 25 C is set by parameter 10036 to 3mV C cell For example for a 24V battery 12 cells of 2V at a temperature of 30 C the voltage compensation is 30 25 12 3 1000 0 18V For a floating voltage value 10005 set to 27 2V the effective floating voltage compensated will be 27 02V 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 24 V 3 2 0 User manual Studer Innotec SA VarioTrack 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 1 bulk 2 absorption and 4 floating as per the figure to the Ubatt V 1 right These factory parameter values of the VarioTrack 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 LLELELULEETLCHECEE LE 1 4 C E T 13 6 27 2 54 4V equivalen
18. 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 VarioTrack 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 of the voltage thresholds applied immediately If a BSP battery probe next to the battery is used a BTS 01 is not necessary The BSP module is fitted with a temperature sensor If both elements BTS 01 and BSP are present only the BTS 01 is taken into Auxi Aux account to correct the battery temperature max 300m 9 3 AUXILIARY RELAY MODULE ARM 02 By connecting the external auxiliary relay module to the VarioTrack plug 6 provides the solar charge controller with 2 additional relays If the plug 6 is already occupied by the BTS temperature sensor you have to unplug it to connect the ARM and thereafter plug the BTS in the free slot of the ARM Each auxiliary relay has change over contacts with programmable activation The maximal authorized currents and voltages for these contacts are 16A for 230VAC 24Vdc and 3A for 50Vdc When a contact is activated the corresponding LED lights up There is no dedicated function assigned to these relay To assign program fun
19. the logic combination mode AND or OR To exit the selected relay field press ESC Manuel utilisateur V 3 2 0 27 Studer Innotec SA VarioTrack These information fields are visible even if the auxiliary relay ARM 02 see chapter 9 3 is not connected 8 2 2 Displaying the operating mode of the equipment Info n 11016 Night the solar generator voltage or luminous intensity is not enough to start the equipment When this indication appears during the day it means a generator fault wiring Start up the solar generator or luminous intensity is not enough to start the equipment but sufficient to produce power This indication only appears in the morning or in the evening Charger the charger operates normally at the maximum power point of the solar generator Charger U the charger operates in voltage regulation absorption equalization or floating In this status it is normal to see a current lower than the maximum possible Charge I the VarioTrack has reached the maximum allowed current fixed by the parameter 10002 battery charge current In this status the power of the generator is limited to a lower value then the maximum possible Charge T the maximum permissible temperature of the VarioTrack is reached and the power is limited by the temperature This status is not a problem but may highlight that the system performances could be enhanced by reducing ambient temperature or if the model is a VT 65 by addin
20. 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 Under no circumstances should PV module inputs of several VarioTrack be put in parallel In multi unit systems connected to the same communication bus all VarioTracks must be connected to the same battery bank When the VarioTrack units are not synchronized they must be programmed in the same way and it s recommended to not activate the periodical equalization tunction The equalization can be manually started or will be done by the synchronized units In multi unit systems each VarioTrack 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 VarioTrack 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 If 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 the battery manufacturer and under the responsibility of th
21. 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 this 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 Manuel utilisateur V 3 2 0 7 Studer Innotec SA VarioTrack No person is authorized to proceed with any change modification or repair of the equipment without the prior written authorisation of Studer Innotec 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 The VarioTrack can be installed at altitudes up to 3000m For installations at higher altitudes please contact Studer Innotec SA The VarioTrack is in overvoltage category II in accordance with the norm IEC EN 62109 1 2010 that considers all solar generators as being in overvoltage category I 3 MOUNTING AND INSTALLATION 3 1 STORAGE The equipment must be stored in a dry environment at an ambient temperature between 20 C and 60 C Store it 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 a
22. 010 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 4 7 4 Absorption duration 10011 120min Use this parameter to set the absorption duration The absorption phase starts once the set tension 10009 is reached When the time is over see chap 7 2 2 the charger goes automatically to the following authorized phase 8 4 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 at which point the charger automatically passes to the next authorized phase This can be used in order to shorten the period under which a high voltage is applied and thus reduce water consumption 8 4 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 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 The absorption phase c
23. 23 32 34 ES E 34 13101 A 24 35 10020 sse 23 24 34 0010 71 ne 24 32 34 POO 22 A 23 34 OE E EUS 34 7010 6725 A 34 OO a RE 34 002 34 OO chop ately Car ait 35 A810 29 OS 35 EE o steric 35 OOE eee een eee 35 OOE Sn E 35 FOO SA erc ore meto 35 A 35 OO RE REA 24 1100 ias 21 25 32 HO 36 OA cnn RE 35 100523 24 OO Arme 25 29 36 1005 ees eot 32 36 781810 9 EMEN 36 A MEME 37 FOO BG PNE 37 FV OOS Dans 37 OO MEN 38 10092 rennes 38 OO nn 38 OCGA ane en 38 1009 PET 38 HO cece cerns cea cuccecase 38 52 W EZ RE 38 OO 38 OO E 38 A O NEIN ost cts ne 38 OO 38 OC EE 38 ONO er aca 38 HO 38 OM PRE 38 O NN NOE 39 HO EHE 39 Oen ros NE ame 39 LOT eter eere 39 TA este acct ete ten Laie 39 ACs See eee eee 39 OTTA tc 39 COWS A 39 A MARE 39 COMI RR EME 39 TOO ORNARE 39 a 39 ra 7 0 A 39 ENON IT ne 39 A 39 MONDO aan an die stato 39 TOA a ct 39 o ee eae eae ener 39 HO 39 HO 39 A a nen 39 10153 5 9 HMM 39 OBS 39 O NO 39 OS eect castes ee cerca 39 MOA MMC 39 TA e etes 40 OS EE 40 OS en ce 40 DOISS ec cia tees 40 ELE ogra 40 O eee ene 40 O at niece deta 37 OP MEAE 37 11517 RR 37 aaa loss 37 TOTAS h creat acters 38 FO NAGY HN 38 OP es secre nie 38 V 3 2 0 DOMO c une E 38 OA 38 TODO ce e 38 DOT ascen cn 38 LOLS DY irrita 38 WEE EN 38 aU Ci sy MEM 38 TC E E 38 erts ss PME 38 OS aeterne 38 A n EE 38 OS 38 O MENOR arene 39 A NH 39 Did nues ss 39 A S 39 PONG E RE
24. 39 Old 39 LI ns te 39 A AS 39 Op 39 OA ener 39 T0017 2 39 OA a 39 Oo mre 39 42 977 ttavet peasee cea 39 SO eee 39 O 39 MOTZ PEN UM 39 8181 SOM MONEO ERAN 39 2 0157 MAMMA 39 LA A 39 HO E 39 E S e 39 TOUS maa 39 A po 39 NOT GS Verana 39 1018 ee 40 Oo 40 OO cee 40 Reus MN 40 TONG SM MEME 40 O NENNEN 40 TA A 37 Oo NS 38 A AEE N 38 User manual Studer Innotec SA VarioTrack 19 NOTES Manuel utilisateur V 3 2 0 53 Studer Innotec SA VarioTrack 54 V 3 2 0 User manual Studer Innotec SA VarioTrack Manuel utilisateur V 3 2 0 55 y nO Studer Innotec SA Rue des Casernes 57 1950 Sion Switzerland Tel 41 0 27 205 60 80 Fax 41 0 27 205 60 88 info studer innotec com www studer innotec com
25. JU VarioT rack a MPPT solar charge regulator User Manu l or 7 VarioTrack VI 63 H VI 80 12 24 48V 65A 12 24 48V 80A Oo Se eS aa eee Ga MA NN LES kon ls s n d e m EN i 7 ae se a Ez Sa TM a Sm x i E p bs gt a 1 3 B E me I r isl E L p 3 r la Accessories Remote control Temperature sensor Auxiliary cooling fan External auxiliary relay module Studer Innotec SA 2014 V 3 2 0 4098 Studer Innotec SA VarioTrack 2 V 3 2 0 User manual Studer Innotec SA VarioTrack Contents 1 INTRODUCTION Wc dalla M 5 2 GENERAL INFORMATION 5 2 1 ABOUT USE TOU RU o NR RCM Tn ERA 5 2 2 TD ORT GIA SGT SIS UIC TOMS RR T ai 6 2 3 COMMON errr eee eee ee Nea ne ArT iia 6 2 4 CITY CCW CHU ONY ress es rece deoa nt SevsdutsSunscuss Denton feriti DevsberiDreievtedcnten tin tend 6 De Wey 0001702 ere a MERE S m T TT TNR a cites 7 PAD UI A a T 74 2 5 VV CRAIN S and guidelmes is 3 MOUNTING AND INSTALLATION c nica ias 8 3 1 DITS Kee DEA AET E E E T ee ee ee E TET 8 3 2 UE E S E E AEE re tes a ten EAE EIEEE KEREN A eS ELES RONE oN RAN 8 du MOUNA DIO CS AS Ne ds 8 3 4 FITCH SE Mitre Il SO ASS E 4
26. 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 warranty An annual check of all the connection tightness is recommended In 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 VarioTrack maximum current It will be mounted as close as possible to the battery 4 5 MULTI UNIT CONFIGURATIONS Several interconnected VarioIrack units 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 max 15 units via a communication bus see chap 4 8 that uses the connectors 7 and a cable ref CAB RJ45 2 that is maximum 5 metres long When both connectors 7 are used the termination selector 8 must be in O open position If a VarioTrack is connected to another compatible device Xtender VarioTrack VarioString BSP REC Xcom with the same communication bus it is highly recommended to make a software update of all components in the system in order to guarantee all functionalities 16 V 3 2 0 User manual Studer Innote
27. Used The various possible configurations are described in sect 8 1 10 type CR 2032 about 10 years These screws should be tightened to a torque 1 Screw to close the front cover of 5Nm to guarantee the IP rating of the VarioTrack 10 V 3 2 0 User manual 7 Socket for communication cables connections must be carried out only with original Studer cables 4 2 CONNECTION COMPARTMENT il As RCC 02 RECI a Manuel utilisateur V 3 2 0 i Studer Innotec SA VarioTrack eX P A Vario Track PPT solar charger Studer Innotec SA VarioTrack 4 3 PHOTOVOLTAIC GENERATOR PV The VarioTrack may accept input voltages between 0 to 150V max Its 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 protection class Il 4 3 1 Dimensioning The solar generator is dimensioned to cover an important part or the entire power requirement of the system Once the power has been decided 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 opt
28. XILIARY RELAYS ooocoooccconoccconoccconocconacononocononocononoccnonccnnnanos 48 V7 TECHNICAL DAA curia dt 51 17 1 o lla o A A EM IL ME MEM ELEC 5 IZ OUT DARE e prm 5 EAS ENVIO NM daa cies 5 17 4 FI TOS OTE CO ri S 18 INDEX OF PARAMETERS da ads 52 TE ieget 53 4 V 3 2 0 User manual Studer Innotec SA VarioTrack 1 INTRODUCTION Congratulations You are about to install and use an apparatus from the VarioTrack range You have chosen 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 Maximum Power Point Tracking MPPT algorithm the high output and low internal consumption ensure an optimal valorisation of the energy produced by the PV 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 control display and programming unit RCC 02 03 optional allows an optimal setup of the system and guarantees the user a permanent control ov
29. activation after entering night mode 10094 10148 1min e Activation time for the auxiliary relay in night mode 10095 10149 1 min 8 4 12 4 Contacts activated by an event 10096 10150 menu Different states and events within the installation can be used to activate the auxiliary contacts The events can be combined with each other to create complex functions 8 4 12 4 1 VarioTrack ON 10198 10199 no The contact is activated if the VarioTrack is switched ON 8 4 12 4 2 VarioTrack OFF 10091 10145 no The contact is activated if the VarioTrack is switched OFF 8 4 12 4 3 Battery undervoltage 10097 10151 no The contact is activated in the event of battery undervoltage 8 4 12 4 4 Battery overvoltage 10098 10152 no The contact is activated in the event of battery overvoltage 8 4 12 4 5 Earth fault 10099 10153 no The contact is activated in the event of an earth fault 8 4 12 4 6 PV error 48h without load 10100 10154 no The contact is activated in case the battery has not been charged in the last 48 hours 8 4 12 4 7 Over temperature 10102 10156 no The contact is activated in the event of over temperature of the device 8 4 12 4 8 Battery charging in bulk phase Bulk 10104 10158 no The auxiliary contact is activated if the battery is charging in the bulk phase 8 4 12 4 9 Battery charging in absorption phase 10105 10159 no The auxiliary contact is activ
30. an be interrupted if the battery charge current falls below a certain level 8 4 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 described in chap 7 2 4 Manuel utilisateur V 3 2 0 33 Studer Innotec SA VarioTrack 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 4 8 1 Equalization authorized 10017 no Determines whether the equalization phase triggered manually or automatically is allowed or not 8 4 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 1001 7 Once equalization phase is initiated disabling the phase does not stop the equalization To stop the equalization force the transition into floating 10006 absorption 10010 or 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 4 8 3 Battery equalization voltage 10021
31. ase absorption equalization 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 equipment is 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 DISPLAYING THE EQUIPMENT STATUS USING THE REMOTE CONTROL RCC 02 03 8 2 1 Displaying the status of a single unit system llarioTrack The VarioTrack screen allows displaying six values in real time Four values a can be chosen among many measured and calculated Mr Phas 7 Bull values indicated in the table below and two show the status of the Psol 8 22 AE auxiliary contacts b these fields are visible even if an ARM 02 is not La t 12 1 12 1 ud present 3 CE 11 EN el K al 26 V 3 2 0 User manual Studer Innotec SA VarioTrack 8 2 1 1 Choosing the displayed values To choose which values to display press the SET button to enter the first field which will appear in reverse video To modify the field content use the SET button then by using the arrows consult the various displayable values and select them as permanently displayable values in the related field by validating with the SET button When no other value than
32. ased communication sets Xcom LAN Xcom GSmM 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 part of the equipment e Displaying several operating quantities measured or calculated Current Voltage Power etc for each apparatus Updating the software or implementing tailored software Backing up restoring system parameters configuration Loading a parameter file configuration Storing error message history for each device Recording VarioTrack s data and other information essential for the system see chapter Data recorder p 23 in the RCC manual 40 V 3 2 0 User manual Studer Innotec SA VarioTrack RCC O2 RCC O3 CN Wed 6 Ua 5 0 Hac ss 21 1A Cllr ns oe r FF rd 2l 21 Ad dd Remote Control Centre CC 02 ce e Functionalities of the RCC 02 and RCC 03 units are equivalent They differ only in their external aspect The RCC O2 is designed for 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 x I mm RCC 02 170 x 168 x 43 5mm RCC 03 130 x 120 x 42 2mm Both remote control models are supplied with a 2m cable Cables of specific lengths 5m 20m and 50m can be ordered Item reference CAB
33. ated if the battery is charging in the absorption phase If the extended periodic absorption function is activated the contact is also activated in this phase 8 4 12 4 10 Battery charging in equalization phase 10106 10160 no The auxiliary contact is activated if the battery is charging in the equalization phase 8 4 12 4 11 Battery charging in floating phase 10107 10161 no The auxiliary contact is activated if the battery is charging in the floating phase If the extended reduced floating function is activated the contact is also activated in this phase 38 V 3 2 0 User manual Studer Innotec SA VarioTrack 8 4 12 4 12 Battery charging in reduced floating phase 10108 10162 no 8 4 12 4 13 Battery charging in periodic absorption phase 10109 10163 no You can activate the auxiliary contacts on the reduced floating phase and periodic absorption phase in presence of an Xtender and synchronised with the battery cycle 8 4 12 5 Contacts activated by the battery voltage 10110 10164 menu These parameters activate the auxiliary contacts if the voltage drops below a pre defined voltage level during a set time period It is possible to define three voltages linked with three time periods to activate the auxiliary contact The auxiliary contact will only become deactivated when the battery has risen above a certain voltage and a certain time period both values independent of the activation parameters This voltage and
34. ation can be started only during the battery cycle of the Xtender which will then pilot the Variolrack to carry out an equalization phase In synchronized mode the cycle state floating absorption equalization are indicated 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 it is too low inferior to the battery voltage 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 VarioTrack charger turns off and goes in standby mode when this indicator lights up or flashes It will then consume less than 1W The charger automatically switches on again when the sun starts shining and PV voltage goes back above the battery voltage 6 3 CHARGE CYCLE INDICATOR 2 This yellow indicator lights up when the sun is shining and the photovoltaic generator produces enough voltage for charging the batteries Various flashing modes enable to distinguish what phase the regulator is in This indicator lights up continuously during the bulk phase It flashes 1x during the floating phase 2x during the absorption phase and 3x during the equalization phase
35. ax Restore default settings Restore factory settings Parameters saved in flash memory ON of the VarioTrack OFF of the VarioTrack Reset of all VarioTrack Auxiliary relay parameters A list of the auxiliary relay parameters can be found at the end of this manual on page 48 8 4 4 Basic menu 10000 menu 8 4 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 recovering such a battery Manuel utilisateur V 3 20 3l Studer Innotec SA VarioTrack 8 4 4 2 Synchronization of a battery cycle with an Xtender 10037 yes When a Studer 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 4 4 3 Battery floating voltage 10005 13 6V 27 2V 54 4V Determines the voltage applied when the battery i
36. back of the case using 4 screws M 8 mm long and washers see fig hereafter before wall mounting Mount it vertically with the cable glands downward An external cooling fan ECF 01 can be installed before or after the equipment has been mounted on the wall in order to improve its performances 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 9 4 p 42 Manuel utilisateur V 3 2 0 9 Studer Innotec SA VarioTrack 4 WIRING The connection of the VarioTrack charger is an important step of the installation It may only be carried out by qualified personnel aware of the rules and regulations in force The installation must always comply with these standards The cross sections of the cables connected to its terminals must comply with local regulations All cables in use should be isolated with PVC TFE PTFE FEP neoprene or polyimide Make sure that connections are completely tightened and that each wire is connected at the right place The VarioIrack 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 offen possible to charge any other type of battery using proper settings and with the express appro
37. broken and must be replaced by qualified personnel The wiring must be corrected The equipment functionalities must be checked The solar generator is LED error 3 Message 20 see Acknowledge the message and connected to the battery flashes 4 p 28 correct the wiring error input times Reverse connection ofthe LED Night No PV voltage Check and correct the wiring error solar generator to the 1 lit displayed on the battery input RCC he battery is not LED error 3 Message 80 see Acknowledge the message and connected and there is flashes p 28 correct the wiring error an active solar generator times Battery with inactive solar LED error 3 Message 83 see The battery has not been charging generator not connected flashes 6 p 28 for more than 48h Check the or defective times protection devices the wiring of your solar generator or clear the persistent shade snow Voltage of the PV LED error 3 Message 82 see Check the PV wiring see chap generator too high flashes 5 p 28 4 3 2 Caution A volfage higher times than 150V can seriously damage the device If the VarioTrack has been accidentally connected the wrong way 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 and the internal fuse of the VarioTrack that protects agai
38. c SA VarioTrack In 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 coherent battery cycle This synchronisation can be deactivated using a parameter When the devices are in the voltage regulation phase their currents 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 control and monitoring 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 VarioTrack units in parallel The compatibility of the new units can be checked by Studer Innotec if the serial numbers of the equipment of the existing installation are pr
39. ccessing 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 settings and history of the event generated by the equipment 10 4 COMMUNICATION SETS XCOM LAN GSM hese two sets provide the possibility to control the Xtender VarioTrack and VarioString systems via the Xcom web portal anywhere there is internet access via the local network or via the GSM network The access to internet can be done with a smartphone tablette or notebook computer Manuel utilisateur V 3 2 0 43 Studer Innotec SA VarioTrack 11 WIRING EXAMPLES 11 1 VARIOTRACK RCC 02 T a 1 i a e po 3 HIS cle 4 Dino 2 10 o C jo o Di EN zt m nel el Becas uam N parallel ee Y L 11 2 COMMENTS ON THE WIRING EXAMPLES G 10 nverter Charger See chap 10 1 Battery Temperature sensor BTS 01 See chap 9 2 Protective earth Main protective earth protective equipotential bonding connected to the conductive and accessible parts of the building and if possible connected to a standard earth electrode Protective earth for the The equipment is designed to be connected to a equipment protective earth Class I to which they must be connected T2 Protective earth for the battery The battery negative pole must be earthed The other configurations m
40. charge profile that meets at best the requirements 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 compensation 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 30 25 12 3 1000 0 18V a floating set to 27 2V is compensated to a value of 27 02V 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 4 5 1 Synchronization of a battery cycle with an Xtender 10037 yes This parameter appears on the basic menu and is described in chapter 8 4 4 2 When this parameter 10037 is activated all other parameters involved in the battery cycle are hidden and not accessible In this case only the maximum charging current is adjustable 32 V 3 2 0 User manual Studer Innotec SA VarioTrack If an Xtender inverter charger is interconnected Communication to one several VarioTrack the Xtender battery cycle will be imposed to the VarioTrack of the syst
41. ck Anyone who installs or uses a VarioTrack can completely rely on this user manual and is bound 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 This symbol placed on the product indicates that its surfaces may reach temperatures higher than 60 C This symbol placed on the product indicates that its use must follow the instructions in the user s manual 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 xxxxx The value of the parameter
42. contro Inst 10087 Disabling of the display button o Z o No o Manuel utilisateur V 3 2 0 47 Studer Innotec SA VarioTrack 16 PARAMETER LIST FOR THE AUXILIARY RELAYS User Level Parameter Factory value value 10089 Operating mode AUX 1 Combination of the events for the auxiliary 10090 contact AUX 1 Any Function OR a 10091 VarioTrack is OFF AUX 1 Ne 10093 Activated in night mode AUX 1 10094 Delay of activation after entering night mode a o AUX 1 om we dl AC ES Expert 10097 Battery undervoltage AUXI No O Expert 10098 Battery overvoltage AUX 1 NO Expert 10099 Earth faut AUX 1 NO Expert 10100 PV error 48h without charge AUX1 NO Expert 10102 Overtemperature AUX1 No Expert 10104 Buk charge phase AUX No Expert 10105 Absorption phase AUX 1 NO Expert 10106 Equalization phase AUX NO Expert 10107 Footing AUX o NO Expert 10109 Periodic absorption AUX No Expert 10111 Battery voltage 1 activate AUXI No Expert 10112 Battery voltage 1 AUX1 117 284 468Vdc Expert 10113 Delay 1 AUX 0 lmn Expert 10114 Battery voltage 2 activate AUXI No Expert 10115 Battery voltage 2 AUX1 I19 289 A 8Vdc Expert 10116 Deloy 2 AUX 1 1 X omn Expert 10117 Battery voltage 3 activate AUXI
43. ctions to these auxiliary contacts use the remote control RCC 02 03 A description of the necessary parameters is listed in the programming section chap O of this user manual The module is to be mounted on a DIN rail and is delivered with a 5 metre connection cable Cable glands that are not in use must be properly closed If this instruction is not respected the equipment loses its degree of protection IP54 and dust or small animals may enter the equipment causing significant damage which is not covered by the warranty 9 4 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 48 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 exposed to water spray without damage However do not expose if to dirty water splashes in order to prevent mud or similar particles from blocking the mechanism The assembly instructions are supplied with the accessory Aligner l index 42 V 3 2 0 User manual Studer Innotec SA VarioTrack 10 EQUIPMENTS COMPATIBLE WITH THE VARIOTRACKS When making hybrid energy systems VarioTrack units are often combined with Xtender inverter chargers mentioned hereunder They then belong to a system where they are interconnected via the communication bus The full description of
44. d cadmium mercury hexavalent chrome PBB or O PBDE COMPLIANT Pb Free 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 EU Reference standard EN 61000 6 3 201 1 EN 61000 6 1 2007 EN 55014 EN 55022 Low voltage directive 2006 95 EC Reference standard EN 62109 1 2010 RoHS directive 2011 65 EU CH 1950 Sion 13 May 2014 Studer Innotec SA R Studer a 46 V 3 2 0 User manual Studer Innotec SA VarioTrack 15 PARAMETER LIST User Level Parameter Factory value E A Bosic _ 10005 Floating voltage 13 6 27 2 544Vdc Expert 10006 Force phase of floating Expert 10008 Absorption phase allowed Yes Basic__ 10009 Absorptionvoltage 14 4 28 8 57 6V Force absorption phase a RENE Expert 10011 Absorption duration 120 min 10012 End of absorption triggered by the current No 10013 Current threshold to end absorption phase 10 Adc MEN Basic _ 10017 Equalization allowed No Expert 10018 Forceequalization po Y Expert 10019 Equalization before absorption phase Yes Expert _ 10020 E
45. e VarioTrack constantly measures the voltage between the positive pole of the battery and the earth If this voltage is greater than approximately 1V the VarioTrack registers an error Floating battery This option should be used when none of the poles is connected to the earth In this case the Variolrack measures the voltage between the battery positive pole and the earth and voltage between the battery negative pole and the earth If one of the voltages is less than IV the VarioTrack registers an error 4 7 LIGHTNING PROTECTION The VarioTrack has internal protections against lightning by means of surge protection 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 Most of the time damages due to lightning generate significant costs replacement of all the electronics which are not covered by the manufacturers warranty 4 8 CONNECTING THE COMMUNICATION CABLES 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 fo
46. e batteries can be fully charged by the successive phases to 4 described hereunder t h 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 irradiation at the time It is limited to a maximum of 65A for model VT 65 or to 80A for model VT 80 a VT 65 fitted with the external cooling fan ECF 01 It is important that the max battery charge current be set according to the battery specifications to prevent damaging them This current can 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 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 soon 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
47. e 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 user s 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 700Ah 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 14 V 3 2 0 User manual Studer Innotec SA VarioTrack accidental and undesired stopping o
48. e remote control RCC 02 03 If the default parameters factory settings are modified the new values must be reported in the parameter table p 47 at the end of the manual which must remain on the installation site at the disposal of the maintenance personnel When the VarioIrack is connected to other VarioTrack units via the communication bus the settings of the DIP switches must be the same for all the interconnected VarioTrack units 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 Pos no 1 Function ee Function El DIP switches not taken into account Default parameters or those set by the remote control RCC 02 03 are active 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 the table below 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 Manuel utilisateur V 3 2 0 29 Studer Innotec SA VarioTrack Battery type Floating Absorption Equalization 30min ME voltage voltage period ET Open equalization
49. ececccesececcnececesecececesececeueneneeees 35 9492 INSWICVCIE T0026 H MENU e NN core ucasbiate 30 8 4 10 SVSIS A OOS Gt ISO 36 8 4 11 Auxiliary contacts 1 10088 and 2 10142 Meno tanda 37 8 4 12 o o ERIE REESE SAE AE AE AEAEE 37 9 ACCESSORIES 0d 40 9 1 Remote control and programming centre RECG 02 POB 40 9 2 TEMPerarurs Sensorial lalalala 4 9 2 1 Connecting the temperature sensor BTS 01 oooccccccccnnnnnnnnononananananocacononaninonononaninanininoss 42 9 3 FUMIO TEIOY meoesule ARM O27 is 42 9 4 EXISIMGLCOONG TEM EC F OT RP 42 10 EQUIPMENTS COMPATIBLE WITH THE VARIOTRACKS ccccccsssccccssssccccsssccccssssceccesscccesscceeeesecs 43 10 1 Mende Inverness GE ni ico 43 10 2 Battery status processor BSP 5007 EZ0U iss odio neo PR Cn Suo Ene ER Certo gene EDE ture diro uez i OI Sor tevke bus ds 43 10 3 Comminicemomnmogdule Xcorre292I 0 scat t hie sette quio to iret tesa n se iret der pde pert donnes 43 IO 4 ccommuniceolomsels ACOMELA N ESMAS un en eas di 43 IT WIRING EXAMPLES m sous 44 11 1 VOO lc 4 A a a a 44 11 2 Comments ondheswnng axelrmples id AA 44 11 3 VarioTrack Xtender RCC 02 BSP BTS O1hybrid system 45 12 MAINTENANCE OF THE INSTALLATION oooccconoccnoniocnonocononocononocononocononocononocconacononocononcononoccnonicnnnanos 46 VS PRODUCT RECYCLING osa is 46 t4 EC DECLARATION OF CONFORMITY tie Re ao 46 15 PARAMETER LIST ii 47 16 PARAMETER LIST FOR THE AU
50. em This function may be disabled by parameter 10037 If no Xtender is connected to the VarioTrack the latter uses its own setting 8 4 6 Floating phase 10004 menu 8 4 6 1 Floating voltage 10005 13 6V 27 2V 54 4V 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 4 6 2 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 4 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 Over the course of this phase the necessary current diminishes progressively Therefore the VarioTrack does not work at the optimal point of the PV generator because all the available PV power is not required 8 4 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 4 7 2 Absorption voltage 10009 14 4V 28 8V 57 6V Defines the applied voltage during absorption phase 8 4 7 3 Force absorption phase 10
51. er all important parameters for the 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 an independent device but is also designed to be included into a Studer energy system together with the Xtender inverters chargers the BSP battery monitor the configuration and display module RCC 02 03 and the communication module Xcom 2321 Working together these different devices have a synchronised behaviour for a better management of the battery and of the solar resource Please read this manual carefully to ensure the perfect start up and operation of your system 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 It does not contain information about photovoltaic modules PV or batteries of various brands that can be connected For this kind of information please re
52. ert 10148 Delay of activation after entering night mode Peni AUX 2 Activation A for the auxiliary relay in night Expert 10151 Battery undervoltage AUX 2 l No Expert 10152 Battery overvoltage AUX 2 No Expert 10153 Earth faut AUX 2 NO Expert 10154 PV error 48h without charge AUX 2 No Expert 10156 Overtemperature AUX 2 o lo No Expert 10158 Bulk charge phase AUX 2 No Expert 10159 Absorption phase AUX2 NO Expert 10160 Equalization phase AUX 2 No Expert 10161 Floating AUX2 NO Expert 10162 Reduced floating AUX 2 lo No Expert 10163 Periodic absorption AUX 2 No Expert 10165 Battery voltage 1 activate AUX2 No Expert 10166 Battery voltage 1 AUX 2 11 7 23 4 468Vdc Expert 10167 Delay V AUX2 min SC Expert 10168 Battery voltage 2 activate AUX 2 No Expert 10169 Battery voltage 2 AUX2 11 9 23 9 478Vdc Expert 10170 Delay2 AUX2 min O Expert 10171 Battery voltage 3activate AUX2 o No Expert 10172 Battery voltage 3 AUX2 12 1 24 2 48 5Vdc Expert 10173 Delay3 AUX2 1 min Expert 10174 Battery voltage to deactivate AUX 2 13 5 27 54Vdc Expert 10175 Delaytodeactivate AUX2 Omn Expert 10176 Deactivate if battery in floating phase AUX2 No
53. establishing the minimum time between each cycle using parameter 10035 8 4 9 4 Minimum interval between cycles 10035 1h Determines the minimum interval time between each cycle when parameter 10034 activates this function If the parameter 10034 is activated and the interval parameter 10035 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 until the next day and the charger will keep the battery at floating voltage 8 4 9 5 Correction coefficient for battery temperature 10045 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 Manuel utilisateur V 3 2 0 35 Studer Innotec SA VarioTrack and per battery cell For example at 30 C for a 24V battery having thus 12 cells of 2V 30 25 12 3 1000 0 18V a floating set to 27 2V is compensated to a value of 27 02V 8 4 9 6 Battery charging current 10002 80A The VarioTrack 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 bulk phase Note On the VT 65 model the d
54. f the inverter in case of high demand This stopping is due 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 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 The batteries should only be chosen dimensioned and installed by qualified personnel trained in this specific area Lead acid batteries with liquid 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 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
55. fer to the instructions of each specific manufacturer It covers the following models and accessories Charger VarioTrack VT 65 VarioTrack VT 80 Temperature sensor BTS O1 Cooling fan ECF O1 External auxiliary relay module ARM 02 Note The Variolrack 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 65 It is also possible to add the ECF 01 cooling fan on a VT 65 model later see chap 9 4 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 It must remain near the installation so that it may be consulted at any time Manuel utilisateur V 3 2 0 5 Studer Innotec SA 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 VarioTra
56. g the external cooling fan unit ECF 01 see chap 9 4 p 42 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 8 2 3 Displaying security errors Info n 11034 When a security error occurs the device will stop functioning A short text limited to 8 characters will appear on the display indicating which kind of error it is 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 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 below 7V or reversed battery polarity Alarm 80 8 2 4 Displaying the values of a multi unit system When several VarioTrack units are RETIRE Te MULTI Jariol rack cis ci connected to the remote control Le Ubat SG 2 Ude Ubat 56 2 Udel RCC 02 03 the screen VarioTrack N s l Ibat 26 25 Ade MULTI appears displaying the Le consolidated values for all the ill Model Charger connected equipment The displayed pl Psol 1 35 kl values can be selected as per the same procedure described in chap 8 2 1 1 Moreover the units can be viewed one by one by using the arrows up down after the SET but
57. generators this function is useful also to limit the repetition of the equalization cycles When the number of days is reached a new cycle Is not initiated automatically The equalization will take place during the following charge cycle 8 4 8 8 End of the equalization triggered 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 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 equalization duration and the electrolysis phenomenon related to it 8 4 8 9 Final current of the equalization phase 10027 no This parameter determines at which current the equalization phase is considered finished The next phase starts when the charger current goes below this value 34 V 3 2 0 User manual Studer Innotec SA VarioTrack 8 4 8 10 Equalization 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 equalization phase is carried out before the absorption phase t h A equalization voltage B absorption voltage C floating voltage 8 4 9 New cycle 10028 Menu Usually batteries are charged during
58. h 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 Manuel utilisateur V 3 2 0 17 Studer Innotec SA VarioTrack 4 6 1 Detection of earth fault Choosing how to earth the DC circuit is an important factor for the user s safety Once the choice is made the VarioTrack can check the continuity or on the contrary the failure of the earth connection in the case of an IT system In case of failure of the earth connection the equipment turns off and the LED 3 lights up indicating a fault A permanent message requiring validation is displayed on the RCC if present The parameter 10060 establishes the type of earth fault check to be carried out The earth fault check can be set to one of the following three types of earthing schemes or deactivated Negative pole earthed In the Variolrack the negative poles of the PV modules as well as the battery are connected If this option is chosen the VarioTrack constantly measures the voltage between the earth and the negative poles If the measured voltage is greater than approximately 1V the VarioTrack registers an error Battery positive pole earthed Th
59. ill be used to interconnect other VarioTrack chargers in the case of a multi unit application or to connect other types of users who have Studer Innotec s proprietary protocol Xtender BSP In these cases the installation must be switched off and de energized in order to interconnect the units on the communication bus If a VarioString is connected to another compatible device Xtender VarioTrack BSP RCC Xcom with the same communication bus it is highly recommended to make a software update of all components in the system in order to guarantee all functionalities The RCC 02 03 or Xcom 232i should not be placed between two devices connected to the battery Xtender VarioTrack or VarioString E es co ET 1 XTS XTM XTH XTS XTM XTH RCC 02 03 It is imperative 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 If special configurations or settings are required for the system and they are set via internal buttons or switches DIP switch see chap 8 1 they should be set before connecting the PV modules 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 equipment check the polarity A Connecting the battery on the BAT and BAT term
60. imum voltage the PV 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 must be multiplied by 1 1 and divided by the modules Vmpp voltage For example for a system with a VLA type lead acid battery supporting equalization at 60V 60 1 2 17 4 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 model 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 module module module Voc lt 23V Voc 37V Voc 45V Number of modules per string Beware of the PV module tempera
61. inals o Check that the VarioTrack switches on o If there is an REC 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 o Check the operation of the charger and the effective charging of the batteries when it is sunny Your installation is now in operation If the system requires 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 Manuel utilisateur V 3 2 0 19 Studer Innotec SA VarioTrack 5 1 1 Wiring errors and their sympthoms on the the RCC 02 03 correction to be made VarioTrack remote control Polarity reversal of the LED Night 1 No PV voltage Check and correct the wiring error A o nn ne EOI RCC battery on the battery flashes 7x p 28 input The battery is connected No indication If no battery on Check and correct the wiring error to the solar input the input gt Message 80 Reverse connection of the No indication The equipment does not switch on The internal battery to the solar input protection fuse is
62. ioTrachk 17 2 OUTPUT BATTERY VT 65 VT 80 Battery rated voltage 12V 24V 48V automatic or manual setting Battery input voltage range 7 68V Max charging current of the battery at 25 40 C 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 duration floating equalization Battery temperature compensation mV C cell ref at 25 C VarioTrachk VarioTrachk 17 3 ENVIRONMENT VT 65 VT 80 EMC directive 2004 108 EC EN 61000 6 3 2011 EN 61000 6 1 2007 EC Conformity Low voltage directive 2006 95 EC EN 62109 1 2010 ROHS directive 2011 65 EU STUDER proprietary bus and protocol Remote control and programming module RCC 02 03 Communication Isolated RS 232 with Xcom 232i accessory 17 4 ELECTRONIC PROTECTION Polarity reversal of the PV generator Up to minus 150V Polarity reversal on the battery side Up to minus 150V Reverse current night Disconnection by relays Overvoltage on the battery side Up to 150V Over temperature Max 70 C gt power reduction stop Manuel utilisateur V 3 2 0 5 Studer Innotec SA VarioTrack 18 INDEX OF PARAMETERS FO OOO A 31 A t cese detect 31 tT0002 cce sisse 23 36 o PR 32 10005 us 23 24 32 33 CODE 33 A sieges coy 33 9805 RR 23 33 110000 23 24 32 33 FOC VON T 33 FOOL D ie qe as deci 23 33 OO 23 33 Hop ners 33 OO RER 33 NOOT sc
63. 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 The casing of the VarioTrack can reach temperatures slightly higher than 60 C when used for a long period at maximum performance This high temperature can last several minutes after the equipment has been turned off It should be installed in a restricted access area away from children or any unauthorized person 8 V 3 2 0 User manual Studer Innotec SA VarioTrack 3 4 FIXING DIMENSIONS he 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 VarioTrack is installed in a closed cabinet if must have a sufficient ventilation to guarantee that the ambient temperature is kept within the operating limits of the VarioTrack In motor vehicles or when the support undergoes significant vibrations the VarioTrack is to be mounted on anti vibration elements WWQPC The VarioTrack enclosure is fitted with a support plate to be mounted on the
64. isplayed factory value remains 80 A but the maximum effective value will be 65A If no information to determine 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 strings to calculate the capacity the sum of the capacities of a battery of each string has to be taken into account 8 4 10 System 10038 menu 8 4 10 1 Prevents the configuration made by DIP switches 10054 no Blocks the operating mode chosen by means of the DIP switches inside the VarioTrack If Parameter 10054 is set on 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 4 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 Should 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 e No check default value e he negative pole of the batte
65. lusion 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 Voltage higher than 150V across PV or battery terminals Battery reversed polarity across PV input terminals Accidental presence of liquids in the equipment or oxidation due to condensation Damage resulting trom falls or mechanical shocks Modifications carried out without the explicit authorisation of Studer Innotec Nuts or screws that have not been tightened sufficiently during the installation or maintenance e Damage due to atmospheric surge voltage lightning e Damage due to inappropriate transportation or packaging e Disappearance of original identification marks Never take off or damage the rating plate showing the serial number If 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 Studer Innotec 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 Studer Innotec equipment is in any case under the responsibility of the c
66. ment must be returned to the supplier for a check this fault is not covered by the warranty 6 5 CHARGING CURRENT INDICATOR 5 6 7 8 These indicators flash or light up continuously to indicate the current charging range as per the table to the right indicator number indicator The RCC 02 03 remote control allows a complete and detailed display of the VarioTrack behaviour see chap 9 1 22 V 3 2 0 User manual Studer Innotec SA VarioTrack 7 BATTERY CHARGING PROCESS 7 1 GENERAL POINTS The VarioTrack has 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 9 1 p 40 and for some of them a basic 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 lead liquid acid lead gel or AGM batteries The battery charger enters automatically into E 3 operation as soon as the irradiation is sufficient and E the photovoltaic panel voltage is higher than the battery voltage The Charge indicator 2 lights up or flashes depending on the on going charging phase Ubatt V 4 4 Th
67. nd 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 Inmobile applications it is important to select a mounting place that ensures no vibration e Protected from direct solar radiation or heat sources According to the environmental categories defined in the norm IEC EN 62109 1 2010 the VarioTrack can be mounted in a 3rd degree environment PD3 which is in a location with dust pollution The VarioTrack have a high degree of protection IP 54 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
68. nst 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 20 V 3 2 0 User manual Studer Innotec SA VarioTrack 6 DISPLAY SYSTEM The VarioTrack is fitted with a Set button and Vario Track light indicators on the front of the equipment 70 80A MPPT solar charger allowing a clear identification of the operating 50 60A marae iode Float gt Charg Absor 2x 6 1 THE SET BUTTON 4 5 10 20A Equal Night The Set button can be used to start manually 3 ei 2 4 an equalization cycle if this phase is authorized by the initial settings of the equipment The equalization phase will be authorized as from the beep after having pressed the Set button 4 for 2 seconds The Charge light indicator flashes 3x as long as the equalization 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 button 4 for 5 seconds until the second beep turns off the VarioTrack It starts again by pressing the Set button for 5 seconds When the VarioTrack s are connected to an Xtender system and the synchronization 10037 is activated the manual equaliz
69. ovided 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 4 6 EARTHING GUIDELINES he VarioIrack is a Class protection equipment its metal case must be earthed by means of the screw provided between the cable gland LD 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 be earthed The solar generator as well as its wiring must be Class Il isolated Connect PE 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 installed according to protection class I The cross section of the earthed 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 eart
70. 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 Manuel utilisateur V 3 2 0 23 Studer Innotec SA VarioTrack When authorized the equalization phase is carried out at fixed intervals 10052 before the absorption ohase The equalization phase may be applied after the absorption phase by modifying parameter 10019 By default equalization is forbidden because It Is incompatible with gel or AGM type batteries lt 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 The default battery cycle is suitable for a large
71. qualization curent 80Ade o o o o Basic 10021 Equadlizotion voltage 15 6 31 2 624Vdc Expert 10022 Equalization duration 30min J Expert 10025 Daysbetweenequalizations 26days Expert 10026 End of equalization triggered by the eurent No o Expert 10027 Current threshold to end equalization phase lOAdc Expert 10022 Forceanewcycle Y Expert 10030 Voltage level 1 to start a new cycle 12 2 24 4 488 Vdc Expert u under voltage level 1 to start a new 30 min Expert 10032 Voltage level 2 to start a new cycle 118 28 6 4 2Vdc Sc o ae EE Cycingresticted Ves Doer Imo eked delay bauen Ei Thou Expert 10036 Temperature compensation 3mVPC cel Basic 10037 Synchronisation battery cycle with Xtender Yes J Expert 10039 ONofthe Variotrack Y Expert 10040 OFF of the VarioTrack Y Inst 10043 Reset solar production counters Y Inst 10044 Reset daily min max oS 00 S o Expert_ 10051 Reset of all VarioTrack 0000 000 Y Expert _ 10052 Equalization with fixed interval o Yes Expert 10054 Block manual programming dip switch NOT Basic 10056 Restore default settings o Inst 10057 Restore factory settings o Inst 10058 Parameters saved in flash memory Yes J Expert _ 10060 Check Earthing No
72. r at least 1 minute before opening the equipment It is imperative to close the protection cover on the connection terminals after each servicing The VarioTrack is fitted with 2 connectors RJ45 8 7 see chap 4 1 p 10 that enable to transfer information via a communication bus to other VarioTracks or to other equipment such as the RCC or the BSP having the proprietary protocol of Studer Innotec see chap 9 All the units in the network are connected in series strings he 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 18 V 3 2 0 User manual Studer Innotec SA VarioTrack The max accumulated 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 studer innotec com support The communication bus w
73. regulator This device must be supplied by the installer PV modules are often exposed to stormy weather It is highly recommended to install lightning protection see chap 4 7 4 3 6 Cable cross section he connection cable cross section must be chosen according to the short circuit current of the PV generator and the local installation rules A 25mm cross section is recommended Terminals M 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 pulling on the connection 4 3 7 Parallel connection of several VarioTracks As many VarioTrack as necessary 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 disconnection and protection 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 Manuel utilisateur V 3 2 0 13 Studer Innotec SA VarioTrack If several VarioTrack units are connected together by the communication bus it is highly recommended to make a software update of all components in the system to guarantee all its functionalities see chap 9 1 p 40 Solar generators may be of various
74. relays In this case the programmed events for activating the second relay are automatically deactivated The auxiliary contacts are activated and deactivated with a 2 second delay to avoid too frequent switching u Events Commutation he auxiliary contacts react to y PA pd Auxiliary diff t t f amp System contact 1 ifferen ypes O signals 8 Status M nual ON A 0 graphically illustrated below Basic amp events that activate the contacts 3 Manual OFF o N Schedule are 5 5 y p rogram e Simple events 5 E e Scheduled events E e Levels E MM EAS Ll In the following descriptions each parameter has two reference numbers The reference number on the left refers to the auxiliary contact 1 and the reference Events Commutation combination mode Auxiliary number on the right refers to the System contact2 _ Status Manual ON auxiliary contact 2 reference auxiliary contact 1 reference auxiliary contact 2 e Manual OFF my Program MiS Parameters for auxiliary contact 2 8 4 12 Simple functions 8 4 12 1 Switching mode 10089 10143 Automatic The auxiliary contact can be controlled in 4 different ways Manual ON in this mode the contact is permanently activated ON whatever the external conditions or programming Use this function before programming a new function for an auxiliary contact in order to be certain that no o
75. rs 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 4 DESCRIPTION OF THE VARIOTRACK PARAMETERS The parameters of the VarioTrack can be modified in the menu VarioIrack MPPT settings of the RCC remote control This menu allows accessing the following 3 under menus BASIC SETTINGS 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 battery cycle during all its phases SYSTEM MENU gathering a few parameters that are not directly related to the battery cycle such as backing up and restoring the system resetting monitoring setting etc 8 4 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 4 2 Parameter access level All the parameters described hereafter are accessible through 2 different acce
76. rthing 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 equalization carried out indicates the end of the equalization cycle 8 3 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 di
77. ry is earthed e The positive pole of the battery is earthed e Floating battery with no earthed poles In a system with 12V battery the floating battery control should not be activated 8 4 10 3 Reset PV energy meter 10200 This parameter allows you to reset the PV energy meter to zero This could be useful if you wish to measure the energy produced over a given time interval 8 4 10 4 Reset les compteurs de production solaire journaliers 10043 et 8 4 10 5 Reset les min max journaliers 10044 These parameters allow you to reset to zero the different corresponding daily meters This could be useful if you wish to know these values precisely over a specific period of time 8 4 10 6 Restore default settings 10056 signal This signal will restore the initial parameters of the VarioTrack If the installer made specific setting at commissioning this function will restore these settings instead of the factory settings 36 V 3 2 0 User manual Studer Innotec SA VarioTrack 8 4 11 Auxiliary contacts 1 10088 and 2 10142 menu When connected to the ARM 02 module see chap 9 3 p 42 the solar charge controller VarioTrack has two additional external auxiliary relays with potential free dry reversing contacts These two relays make it possible to realize multiple functions with appropriate cabling and simple programming The programming of each contact is made independently apart from when a function requires two
78. s fully charged This voltage prevents self discharge and keeps the battery to its optimum charge level 8 4 4 4 Absorption voltage 10009 14 4V 28 8V 57 6V Determines the battery voltage during the absorption phase See chap 7 2 8 4 4 5 Equalization authorized 10017 no Determines whether the equalization phase triggered manually or automatically is allowed or not 8 4 4 6 Equalization voltage 10021 15 6V 31 2V 62 4V Determines the battery voltage during the equalization phase 8 4 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 4 5 Management and battery cycle 10003 menu The VarioTrack battery charger is designed to ensure a battery charge as complete as possible The charge process Ubatt described in detail in chapter 7 2 is managed in 4 successive 1 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 the figure to the right which represents the basic cycle This basic cycle takes place automatically The charge curve obtained this way depends on a whole t Ih series of parameters that may be freely modified in order to get a
79. sabled either because the Pos 1 off or because the parameter disabling the DIP switches 10054 yes the VarioTrack 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 to an open battery without equalization 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 When the remote control RCC is connected to the VarioTrack by the communication bus it is possible that the software versions are not compatible It is highly recommended to update the software of all components in the system in order to guarantee all functionalities Therefore before starting the setup of the device download the latest software version from our website www studer innotec com on an SD card Follow the instructions in the RCC manual for a successful installation Manuel utilisateur V 3 2 0 29 Studer Innotec SA VarioTrack 8 3 1 The real time clock The VarioTrack features a real time clock that allows among othe
80. ss 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 RCC 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 4 5 Organisation of the configuration menu Level User ref Parameter Basic 10000 BASIC SETTINGS Expert 10054 Block manual programming dip switch Basic 10001 Voltage of the system Basic 10037 Synchronisation 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 Inst 10057 Restore factory settings Expert 10003 BATTERY MANAGEMENT AND CYCLE Basic 10037 Synchronisation battery cycle with Xtender Expert 10002 Battery charge current Expert 10036 Temperature compensation Expert 10004 Floating phase Basic 10005 Floating voltage Expert 10006 Force phase of floating Expert 10007 Absorption phase 30 V 3 2 0 User manual Level Expert Basic Expert Expert Expert Expert Expert Basic Expert Basic Expert Expert Expert Expert
81. t to the off position of the t h DIP switches n 2 3 and 4 when the VarioTrack is configured using the internal DIP switch bank 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 equipment 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 its own setting In the case of an installation with several VarioTracks the battery cycle is also automatically synchronized 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 DIP SWITCHES DIP switch 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 switch bank are not activated the default parameters see list p 47 are applied These parameters can be modified by means of th
82. 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 ts 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 slight battery water consumption In this case the charge cycle is kept in floating phase 8 4 9 1 Forcing a new cycle 10029 signal This parameter enables to force manually a complete charge cycle The Variolrack switches immediately to the bulk phase 8 4 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 12 2V 24 4V 48 8V Duration under voltage 1 for a new cycle 10033 30min Voltage 2 for a new cycle 10032Y 11 8V 23 6V 47 2V Duration under voltage 2 for a new cycle 10033 2min 8 4 9 3 Maximum limit of the cycle repetition 10034 Yes The repetition of the charge cycles can be limited
83. the one initially displayed in the field is selected ESC key validates the initial choice The four fields can be scrolled and modified any time to display four of the values indicated in the table below Info no Name umt Desemption OOO Power of the PV generator 11016 Mode Operating mode Night StartUp Charger Security OFF Charge Charge V Charge Charge T Type of error No Error BatoverV Earth No Batt OverTemp BatOverV PvOverV Others 11037 Number of days before next equalization 11038 Bicis Text Battery cycle phase Bulk Absorpt Equalize Floating R float Per abs 11066 ae Text Synchronisation state XTslave VTslave Y VTmaster Autonom VSslave VSmaster 11069 VS state State of the VarioTrack Off On these values can t be displayed in the multi unit display They will be visible while going in the sub screen of the Multi unit display showing every unit individually 8 2 1 2 Displaying the triggering source of the auxiliary relays To view the actual triggering source of the two auxiliary relays press the SET button and use the up down arrows to navigate down to the two relay fields b Select one of the two relays and press SET to view the information indicating the cause of the last relay activation if the relay is presently activated or deactivation if the relay is presently deactivated The display also shows
84. ther function will activate the contact unintentionally Manual OFF in this mode the contact is permanently deactivated OFF whatever the external conditions or programming Automatic in this mode the auxiliary contact is activated according to the conditions and restrictions of its programming Reversed automatic in this mode the conditions and restrictions define the deactivation of the relay 1 1 1 1 Reset of the programming 10141 10195 signal This function erases the programming of the indicated auxiliary contact Once completed the auxiliary contact is completely deactivated Be aware that this action cannot be undone 8 4 12 2 Combination of events mode 10090 10144 OR This parameter defines how various events intended to activate the auxiliary contact are combined The contact can be activated either by a single event OR function or by all events being fulfilled at the same time AND function Manuel utilisateur V 3 2 0 37 Studer Innotec SA VarioTrack 8 4 12 3 Contacts activated in night mode 10092 10146 menu The auxiliary contact can be activated with the function night mode When the night mode is activated and the activation delay is up the auxiliary contacts will be active for a predefined time period If the activation time is set to zero the auxiliary contact will remain permanently activated until the end of the night mode e Activated in night mode 10093 10147 non e Delay of
85. this equipment is available on our website www studer innotec com 10 1 XTENDER INVERTERS CHARGERS The VarioTrack is compatible with the entire Xtender range and it allows making PV generator or PV network hybrid systems that are perfectly coherent The communication between the Xtender s and the VarioTrack s allow synchronizing the charging cycles of both systems 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 or the charger mode is prohibited On the other hand if the Xtender is turned off using the main ON OFF button de energized the VarioIrack 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 the 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 It calculates and supplies the system with all the information obtained from these measurements 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 a
86. time period for deactivation is also programmable e Voltage 1 active 10111 10165 no e Voltage 1 10112 10166 11 7V 23 4V 46 8V e Duration 1 10113 10167 Imin e Voltage 2 active 10114 10168 no e Voltage 2 10115 10169 11 9 V 23 8V 47 6N e Duration 2 10116 10170 10min e Voltage 3 active 10117 10171 no e Voltage 3 10118 10172 12 1V 24 2V 48 4V e Duration 3 10119 10173 60min e Voltage for deactivation of the auxiliary contact 10120 10174 13 5V 27V 54V e Duration over batter voltage for deactivation 10121 10175 60min e Deactivation if the battery is in floating phase 10122 10176 no 8 4 12 5 1 Deactivation if the battery is in floating phase 10122 10176 no If you activate one of the auxiliary contacts according to the battery voltage you can force deactivation if the battery enters the floating phase This way the auxiliary contact will be released even if the deactivated voltage is not reached or the deactivation time hasn t passed 8 4 12 6 Contacts activated according to the battery temperature 10123 10177 menu You can activate an auxiliary contact according to the battery temperature This function is available with the battery temperature sensor BTS 01 or with the battery status processor BSP Two distinct levels allow the contact to switch ON and OFF at different temperatures e Contact activated with the battery temperature 10124 10178 no e Ac
87. tivation temperature for the auxiliary contact 10125 10179 3 C e Deactivation temperature for the auxiliary contact 10126 10180 5 C 8 4 12 7 Contacts activated on the battery s state of charge SOC 10128 10182 only available in the presence of a BSP menu You can activate the auxiliary contacts according to the state of charge of the battery SOC If the SOC falls below the set level the contact will be activated A time period can be associated with the SOC level to stipulate that the battery must be below the set level a certain time before the contact is activated The contact is deactivated when the battery s SOC rise above the pre set level which can also be associated with a time period The contact may also be deactivated when the battery reaches the floating phase e Contact activated at SOC 1 10129 10183 no e Contact activated below SOC 1 10130 10184 50 e Duration 1 10131 10185 12h e Contact activated at SOC 2 10132 10186 no e Contact activated below SOC 2 10133 10187 30 e Duration 2 10134 10188 0 25h Manuel utilisateur V 3 2 0 39 Studer Innotec SA VarioTrack e Contact activated at SOC 3 10135 10189 no e Contact activated below SOC 3 10136 10190 90 e Duration 3 10137 10191 0 25h e Contact deactivated below SOC 10138 10192 90 e Deactivation time 10139 10193 0 25h e Deactivation if the battery is in floating phase 10140 10194 no
88. ton 2x when the cursor in reverse video is pointing to the field MULTI 8 2 5 Displaying messages and event history The message system is the same as for an Xtender inverter and the alarm messages intormation are stored and displayed in the Event history window See user manual for the RCC 8 2 5 1 Message list Alarm 000 low battery voltage the battery voltage is lower than 1 66V element The VarioTrack continues to operate 28 V 3 2 0 User manual Studer Innotec SA VarioTrack 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 off It 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 earth fault the battery ea
89. ttery 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 as close as possible to the battery The recommended cross section is valid for lengths up to 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 4 4 4 1 Internal fuse The VarioTrack has an internal fuse only on the positive terminal of the PV connection This device protects 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 reverse battery connection on the solar input Before replacing the internal fuse make sure that the solar generator is disconnected from the VarioTrack The fuse may consist of 4 car fuses 30A 80V or be one single blade fuse 100A 80V given the version of the PCB you have These fuses should be should be replaced by fuses of the same type Littlefuse or Pudenz FKS 166 7000 530 or equivalent for the 4 car fuses PUdenz 156 5611 6101 or equivalent for the blade fuse
90. ture The above values are for modules under standard test condition STC 4 3 3 Parallel connection of PV module strings To get the required charging power 2 or more strings are usually to be Maximum connected in parallel Each string connected in parallel shall be recommended power for composed by the same number of modules of the same type the solar generator The number of strings connected in parallel depends on the power of Battery VT 65 VT 80 each module The sum of the power of all the panels connected to a E 2000W 2500W Variolrack should not exceed the power that the VarioTrack can charge see table to the right 4000W 5000W 12 V 3 2 0 User manual Studer Innotec SA VarioTrack 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 and rounded down to the lower value For example in a 48V system with strings composed of 5 in series modules of 110W connected to model VT 65 4000 550 7 3 gt 7 strings 3850W can be put in parallel These strings of 5 modules in series may become 9 when connected to model VT 80 If 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 Variolrack has a current limit
91. ust meet the recommendations at chap 4 6 BI BRO sr manual Studer Innotec SA VarioTrack Protective earth for the solar The protective earth for the PV generator and its generator lightning protection device are connected separately to the main protective earth local equipotential Protective earth for the generator Most often within a hybrid installation it is or the AC source recommended to connect the earthing of the whole frame and the earthing of the lightning protection device to the main protective earth T not described in this manual described in this manual National installation standards specific to the chosen application field must absolutely and as a priority be respected under the installer s responsibility 11 3 VARIOTRACK XTENDER RCC 02 BSP BTS O1HYBRID SYSTEM Q PV generator PV generator XTM U Xtender co 4Ht his na O Manuel utilisateur V 3 2 0 45 Studer Innotec SA VarioTrack 12 MAINTENANCE OF THE INSTALLATION Except for the periodic check of the connections tightening general condition the VarioTrack does not require any particular maintenance 13 PRODUCT RECYCLING The Variolrack meets the European directive 2011 65 EU on A hazardous substances and does not contain the following E HS elements lea
92. ustomer 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 Studer Innotec reserves the right to make any modifications to the product without prior notification Studer Innotec 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 VarioTrack 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
93. val 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 imperative to close the protection cover on the connection terminals after each servicing 4 1 ELEMENTS OF THE CABLE COMPARTMENT No Description Comments Qe This connection must be done using a Terminal to connect the battery positive i i protection and disconnection device if the pole pole has not been earthed 1 E This connection must be done using a Terminal to connect the battery negative gt Sl protection and disconnection device if the x pole has not been earthed Terminal to connect the solar generator The solar generator wiring must be carried out 3 negative pole f Terminal to connect the solar generator in compliance with the voltage and current positive pole A cor E Fuse 4 x 30A 80V or fuse 1 x 100A 80V See 5 EET sect 4 4 4 1 Socket for BTS 01 battery temperature Only the mentioned original accessories can sensor and ARM O2 auxiliary relay be connected to this connector See chap 9 amp module accessories 10 RJ45 connector used for connecting equipment of the Xtender family These The switch must be placed in position O towards 9 when both connectors 7 are

VarioTrack MPPT solar charge regulator VarioTrack

Contents

Download Pdf Manuals

Related Search

Related Contents