Manual - Energy Matters
Contents
1. example battery minus may be connected to this earth Connec ting to other minus connec tions module or load bridges control elements and the fuse This causes malfunctions or even irreparable damage to the controller In systems with preset load minus earth e g grounding antennas all other components must be floating A Seca Batterieladesysteme Printed in Germany Prazisionselektronik GmbH Subject to change without notice D 87700 Memmingen Environmentally friendly chlorine free bleached paper Germany 122. sections 4 1 4 4 Before assembly ensure that all preparatory measures have been taken Do not start assembly until you are sure that you have understood the technical details in the manual Perform the work only in the order prescribed by this manual 2 e The manual must also be available to third parties for all work performed on the system This manual is a component of the charge controller and must be included with it when sold on 1 4 Exclusion of liability The manufacturer cannot monitor the compliance to this manual as well as the condi tions and methods during the installation operation usage and maintenance of the charge controller Improper installation of the system may result in damage to property and as a result to bodily injury Therefore we assume no responsibility and liability for loss damage or costs which result or are in any way related to incorrect installation improper operation and incorrect use and maintenance Similarly we assume no responsibility for patent right or other right infringements of third parties caused by usage of this charge controller The manufacturer reserves the right to make changes to the product technical data or assembly and operating instructions without prior notice 2 Charge controller with fuzzy logic 2 1 Overall function of the charge controller in the PV system The charge controller is used in PV power supplies with battery bank for the hobby and leisur
3. LED 1 Info for ope LED 2 Battery for charge status rating status and fault load shedding and early warning messages O o CIO Plug in fuse O olo 010 0 8 A controller 10 A ra m ds 12 A controller 15 A 20 A controller 20 A Integrated tempe 30 A controller 30 A rature sensor Connection terminals Figure 1 Cyclical charging lead and gel The charge controller raises the end of charge voltage for approx 1 hour for the next charging cycle after the SOC falls below 70 12 4 V Equalizing charge lead only When the charge status SOC falls below 40 11 7 V equalizing charging is activa ted During this stage the end of charge voltage is raised for approx 1 hour the elec trolyte which prevents acid stratification is mixed and thus extends the service life of the battery bank This equalizes all cells and extends the service life of the battery bank Monthly charging Depending on the setting lead or gel the corresponding increase of the end of charge voltage is maintained over 1 hour every 30 days Temperature tracking of the end of charge voltage As the battery temperature increases the optimum end of charge voltage of lead acid batteries decreases At high battery temperatures a constantly set end of charge voltage leads to uncontrolled gassing Temperature tracking reduces the end of charge voltage at high temperatures and raises them at low temperatures Temperature tra cking wi
4. N VDE 0510 Part 2 sections 7 Precautions against explosion hazard 8 Precautions against dangers from electrolyte 9 Storage e National Electric Code with article 690 Choose the installation location in accordance with the following criteria e Protect the charge controller from direct weathering e Avoid direct exposure to sunlight and heating from adjacent devices Ensure that the device is not subject to dirt or moisture Install it as close to the battery as possible safety clearance at least 30 cm Solar modules Battery Load Figure 3 Overview of connections 4 2 Securing the charge controller When securing the charge controller ensure that the cooling element is well ventilated e Install the charge controller so that the cable openings are at the bottom Ensure that no objects are within the 100 mm clearance space above and below the device Secure the charge controller appropriately Mount the charge controller to the wall using the holes in the housing cooling element with screws The charge controller is designed without strain relief so that the conductor cross section can be adapted for the local conditions For this reason strain relief e g cable clips must be put in place approx 100 mm below the controller before the cable looms can be distributed to the individual componen
5. PHOTOVOLTAIK PHOTOVOLTAIC PHOTOVOLTAIQUE FOTOVOLTAICA Operating instructions Solar Charge Controller 8A 12A 20A 30A UK i di 716 140 05 44 ve Contents Safety instructions and exclusion of liability Charge controller with fuzzy logic Configuration Installation Operation Maintenance Malfunctions Manufacturer s warranty Technical data 0 Protective functions of the controller 1 Charge controller schematic diagram i OM BN 1 Safety instructions and exclusion of liability 1 1 Safety instructions are identified as follows e In this manual safety instructions for personal safety are identified with this 1 symbol e Instructions which relate to the functional safety of the system are in bold type 1 2 General safety instructions For your own safety the following points must be observed during installation When laying cables ensure that no damage occurs to any of the constructional fire safety measures present in the building There are more detailed instructions in 4 4 System wiring The PV components may not be installed and operated in rooms where highly flammable mixtures e g from gas bottles paint lacquer solvents etc may be present Do not store any of the mentioned mixtures in rooms in where PV components are installed Avoid sparking when working on the system Solar modules generate electricity under incident light The f
6. e residential business commercial and small company areas The charge con troller monitors the charge status of the battery controls the charging process and the connection disconnection of the loads This allows the battery use to be optimised and its service life to be significantly extended The charge controller is set for lead batteries with liquid electrolyte on delivery and can be switched to a setting for batteries with so lid electrolyte The charge controller can be used for all solar modules to the maximum connection value of the module short circuit current 2 2 Monitoring and control functions SOC calculation Using a special new algorithm the controller can learn the characteristic curve of the battery After this learning phase the SOC charge status of the battery is indicated with an average precision of approx 90 This charge status is the basis for most control and monitoring functions Overcharge protection Frequent overcharging damages the battery bank The charging process and the over charge protection are therefore controlled by a new hybrid actuator with pulse width modulation to guarantee gentle charging of the battery Voltage recognition A special measurement process renders battery sensor lines The voltage drop on the battery line is compensated out after the first full charge
7. he device m Grounding The components in stand alone systems do not have to be grounded this is not standard practice or may be prohibited by national regulations e g DIN 57100 Part 410 Prohibition of grounding protective low voltage circuits See point 10 for further information m Cutting to size All conductors must be cut to size before connection Shortening Remove isolation on both sides and squeeze core end sleeves open if necessary e Cover the free conductor ends which are not to be connected immediately with isolating tape e Mark the end of each conductor Module cable M M Battery cable B B Load connection cable L L Connect the module and string cables to the connection sockets of the PV modules only in accordance with the manufacturer s instructions Wire the device in the following order to avoid malfunctions Battery Modules Load m Connecting the battery bank to the charge controller e Remove the fuse in the controller e Wire the battery connection cable A A in parallel between the charge controller and the battery bank Connect the battery connection cable to the terminal pair of the charge controller Ensure that the polarity is correct Fit holders for external floating fuses to the battery connection cable close to the battery pole 8 A controller 10 A 12 A controller 15 A 20 A controller 20 A 30 A controller 30 A IH 0 Do not i
8. i 10 m m 9 10 m m 9 2 1 2 1 4 m m j3 4 3 Voltage setting 6 5 6 5 8 m m 7 8 m m 7 10 m m 9 10 m m 9 Lead Position 3 4 may Gel When switching to not be occupied To do using gel batteries the so either remove the blue blue jumper must be jumper or place it on 4 6 changed from 4 6 to 3 4 factory setting 3 5 Night light function If the controller is used in lighting systems the so called night light function can be programmed If this function is activated all loads are connected at night and discon nected during the day The deep discharge protector remains activated Remove the jumper which connects contact pins 1 2 to activate the night light function Store the short circuit plugs jumpers safely so that you can return the controller to the basic setting Night light function OAAN a a on uw a 10 m m If you do not wish to attempt to configure the controller yourself please contact your specialist dealer No liability can be accepted for damage of any kind caused by an incorrectly set charge controller 4 Installation 4 1 Choose a suitable location Do not install and operate PV components in rooms where highly flamma ble gas mixtures can occur Explosive oxyhydrogen gas can form near the battery Ensure that the area around the battery is well ventilated and avoid sparking Observe the regulations for batteries The following must be observed in particular e DI
9. ion If the battery is not connected to the controller open circuit operation fuse faulty bat tery connection interrupted and the solar module supplies more power than the load requires both LEDs light red If the solar power generated is less than the consumption the load is activated periodically At night both LEDs are switched off The controller is protected against open circuit operation However to guarantee safe start up after this open circuit operation the following steps are absolutely necessary gt Disconnect the solar generator minus connection from the solar charge controller gt Remove the fuse and insert it again restart Connect the solar generator again 8 Manufacturer s warranty The manufacturer assumes the following guarantee obligations to their end users The manufacturer will remove all manufacturing and material faults that occur in the charge controllers and affect the correct functioning of the device during the guarantee period Natural wear and tear does not constitute a malfunction No guarantee can be offered if the fault was caused by the end user or by third parties in an attributable manner after the purchase contract is made with the end user especially by unprofes sional installation or commissioning incorrect or negligent handling excessive loading use of improper equipment faulty construction work unsuitable construction location or improper operation or use Guarantee claims shall o
10. nly be accepted if the specialist dealer is notified of the fault immediately after it is discovered The manufacturer must be notified of the fault via the specialist dealer A copy of the proof of purchase must be enclosed A precise description of the fault is required for faster processing The guarantee expires 24 months after the purchase contract was made by the end user unless the manufac turer expressly agrees to extend the period in writing The dealer s guarantee based on the purchase contract with the end user is not affected by this guarantee obligation The manufacturer can choose to fulfil the guarantee either by repair or replacement This does not include the costs incurred for exchange ship ping or re installation If the product can neither be repaired or replaced or if this does not occur within a suitable period in spite of the specification of an extension period in writing by the customer the reduction in value caused by the fault shall be replaced or if this is not sufficient taking the interests of the end customer into consideration the contract is cancelled Any further claims against the manufacturer based on this guarantee obligation in particular claims for damages due to lost profit loss of use or indirect damages are excluded unless liability is obligatory by law 10 9 Technical data Charge controller type ma moane short circuit curren
11. nsert the fuse yet Connect battery connection cable A to the plus pole of the battery Connect battery connection cable A to the minus pole of the battery Insert the fuse Not included Connecting the solar generator to the charge controller Connect the module connection M M to the screw type termi nals of the charge controller Ensure that the polarity is correct Only connect solar generators as energy sources no power supply units diesel or wind generators m Connect the loads Protect every load circuit with a fuse Disconnect all loads before connecting the load conductor remove the fuse to prevent sparking Connect the load conductor to the screw type terminals of the charge controller Ensure that the polarity is correct Connect loads which may not be switched off by the charge control ler shedding the load e g emergency light radio connection directly to the battery This increases the risk of deep discharge which is no longer controlled by the charge controller Protect these loads with a separate fuse Then secure all cables with strain relief in the immediate vicinity of the charge control ler Fit strain relief for the other components also 5 Operation 5 1 Testing and commissioning Check the following items after wiring Correct polarity at all connections cable labels Secure fit of all cable connections e Correct function of all strain relief fittings e Pa
12. r protec Info LED Reset Technical tion tive measures data Normal Everything OK None Green No reset operation flashing Surge current Too much load Load deactivated Red green Switch off or discon 110 load current flashing nect load 1 rectify fault reactivate Surge current Module current Load deactivated Red yellow Automatic when sur 110 module too high flashing ge current no longer present Overheating Controller Load deactivated Steady red Automatic when tem Internal overheated light perature drops 2 temp 85 C Battery Battery voltage Load deactivated Yellow Automatic when 15V overload too high module short flashing voltage drops 30V circuited Battery Battery voltage Load deactivated Red Automatic when 10 5V voltage too too low no flashing voltage increases 21V low battery faulty fuse Open circuit No battery Load deactivated Both LEDs Disconnect solar operation connected steady red generator and replace fuse faulty fuse see chap 7 1 1 The surge current deactivators are emergency functions which protect the controller from irreparable damage When sizing the system ensure that the max module and load currents permitted are not exceeded 2 If the controller overheats check whether the device is sufficiently cooled and ventilated at the installation location 3 The most common causes of battery overloading are charge sources connected directly to
13. rallel wiring of the battery connection cables Tightness of all screw and terminal connections Starting the system gt Insert the fuses at the charge controller and battery and wait until the left LED flashes green after 2 min at latest gt Remove the cover of the solar generator The loads only work when the right LED lights permanently or flashes rapidly 5 2 LED operating status displays e Charge status display SOC The colour of the right LED indicates the charge status of the battery The colour changes in ten steps from red approx 0 charge status to yellow approx 50 to green approx 100 Deep discharge warning When the charge status falls below 40 the right LED flashes rapidly 10 x faster than the left LED to warn the user of the risk of load deactivation Deep discharge deactivation The right LED flashes slowly approximately the same frequency as the Info LED to indicate that the deep discharge protector has deactivated the load The device is disconnected when the charge status reaches 30 LED lights red yellow The load is automatically reconnected when the SOC reaches 50 LED lights yellow The charge status can also be identified based on the colour while the LED is flashing Information LED The information LED flashes green during normal operation A red colour indicates that there is a fault The fault can be determined using the table Fault descrip Controlle
14. ronically protected Load is deactivated automatically Measures Wait until a permitted operating status has returned The controller automatically reactivates the load Undervoltage Electronically protected Load is deactivated automatically Measures Wait until the battery is sufficiently recharged The controller automatical ly reactivates the load Operation without battery Electronically protected The controller is protected its functions are limited Measures see 7 2 Incorrect polarity of a module Electronically protected The charging process is automatically interrupted Measures Connect the module correctly 11 11 Charge controller schematic diagram The following sections only describe the technical grounding options The goal is to maintain the controller functions The in stalling engineer must note and observe the national regulations in the region of use The loss of the protective low voltage status caused by grounding must be compensated by correspon ding isolation measures for live parts protection against direct contact If the plus side is selected for grounding it can also be used as an earth for all system components All plus conductors are internally interconnected in any case Only one connection can be grounded from the minus connections of the module battery and load components If your solar system already provides a minus side earth only one component in this
15. sed for batteries with liquid electrolyte Equalization charging is generally deactivated for batteries with solid electrolyte Follow the instructions of the battery manufacturer black gt 2 1 Basic setting 4 3 blue gt 6 als red gt 8 7 10 m 9 3 3 Direct connection to the battery If other chargers or an inverter are connected to the battery the charge status is no lon ger displayed correctly The controller can be switched to voltage controlled regulation just like standard products After this is changed only the battery voltage is evaluated to determine the charge status All functions are activated via voltage levels including the charge status display LEDred 10 8 V LEDyellow 12 0 V LEDgreen 13 2 V The charge status LED functions as a colour multimeter in this setting Direct connection to the 2 1 alelal3 battery 6 5 2 1 Tip For storage connect jum 8 m m 7 4 pers which are not required 10 m m 9 6 5 to one pin only Change the red jumper from 7 8 to 5 6 The blue jumper on 4 6 cannot stay in the factory setting and must be repositioned as described in the Selecting the battery paragraph 3 4 Selecting the battery The following jumper settings are required depending on the battery used and the charge controller Lead battery Gel battery 2 1 2 1 SOC setting 4 8 3 4 3 6 m 5 6 m m 5 8 Z 8 Z
16. t 8A 12 A 20 A 30 A Max load current at 50 C 8A 12A 20A 30A Terminal dampa 16 25 mm 4 6 AWB fine wire single wire Weight 420g Measurements 188 x 106 x 49 Protection class IP 22 System voltage 12V 24V Permitted ambient temperature 25 C 50 C Algorithm data AtonlC SOC oriented Voltage oriented Deep discharge warning SOC lt 40 11 7V Load shedding SOC lt 30 11 1V Shift in SOC gt 50 12 6V Equalization loading 14 7 V SOC lt 40 11 7V Cyclical loading 14 4 V SOC lt 70 12 4 V End of charge voltage 13 7 V 13 7 V Temperature compensation 4 mV K cell 4 mV K cell The voltage must be doubled when used in 24 V systems 10 Protective functions of the controller The solar controller has the following protective functions Short circuit at the module Electronically protected The charging process is automatically interrupted Measures Connect the module correctly The controller automatically continues to work Incorrect polarity of the battery Plug in fuse is triggered Measures Connect the battery with correct polarity Replace the plug in fuse see 7 1 Short circuit at the load output and or surge current Electronically protected Information display flashes red green see 5 2 Measures Disconnect the load cable and wait until the information display switches from red green to green flashing Reconnect the load cable Surge current overheating overload of the module Elect
17. th the sensor integrated in the solar charge controller also functions for cyclical charging and equalizing charging The end of charge voltage is never raised above 15 V in order to protect the loads e g equalizing charging at low temperatures Display Two LEDs provide information on the operation mode of your PV system LED 1 Info LED shows the controller status LED 2 Battery LED shows the battery status Deep discharge protection Deep discharge causes your battery to lose capacity due to sulphation The charge controller deep discharge protector disconnects the loads at SOC lt 30 11 1 V The loads are automatically reconnected at a charge status of 50 3 Configuration 3 1 Adjusting the charge controller The solar charge controller automatically adjusts to the system voltage 12 V 24 V when it is installed The controller is set for use with lead batteries with current charge status calculation on delivery This must only be changed in the following cases Direct connection of a main load to the battery see 3 3 Use of a gel battery see 3 4 Activation of the night light function see 3 5 The charge controller is set using short circuit plugs jumpers which connect two adjacent contact pins to one another These are at the top left of the PCB Figure 2 Figure 2 Jumper 3 2 Basic setting Equalization charging is activated in the charge controller on delivery i e it is optimi
18. the battery As a precaution loads are switched off as they are often irreparably damaged by excessive voltage 6 Maintenance The charge controller is maintenance free Inspect the entire PV installation at least once a year in accordance with the manufacturer s specifications Dust controller and cooling element and ensure that the cooling element is sufficient ly ventilated e Check all strain relief fittings Ensure that all cable connections are securely fastened Tighten screws if necessary 7 Malfunctions A range of measures protect the charge controller from irreparable damage In spite of this you must take great care to ensure that the charge controller is used properly Some malfunctions are indicated via the information LED However only faults for which the system is properly installed can be displayed If faults other than those described occur first check whether the controller is connected to the battery the module and the loads with the correct polarity Then check whether the fuse is faulty The controller automatically switches off the load when faults occur 7 1 Changing fuses Follow these steps in the correct order to change a fuse gt Disconnect the solar generator minus connection from the solar charge controller gt Remove the faulty fuse and insert a new one the left LED flashes green gt Reconnect the solar generator to the solar charge controller 7 2 Starting after open circuit operat
19. ts 4 3 Preparing the wiring Ensure that the diameter of the wires matches the power output of the controller The values of the following table specify the minimum cross sections required from the controller to the module distributor box approx 10 m to the battery approx 2 m and to the load distributor socket approx 5 m Controller Load Cross section AWG Isolation 8A 8A 6 mm 10 85 C 12A 12A 10 mm 8 85 C 20A 20A 10 mm2 8 85 C 30A 30A 16 mm 6 85 C Before you start wiring ensure that e the batteries to be used are suitable and correctly connected check the system voltage e the maximum solar power of the solar generator does not exceed the connection value of the charge controller 4 4 Wiring Solar modules generate electricity under incident light The full voltage is present even when the incident light levels are low Fasten a light proof cover securely over the solar modules with adhesive tape The cover allows the voltage level of the modules to be reduced to zero The voltage level of the solar modules may never be reduced to zero by short circuiting them Use well isolated tools only Never touch open conductor ends Isolate any unisolated conductor end which is not connected immediately Only work when the floor below is dry The components solar modules wires etc may not be wet or moist on installation Ensure that the polarity is correct when wiring t
20. ull voltage is pre sent even when the incident light levels are low Work carefully and observe the appropriate safety precautions During assembly and electrical connection in the DC circuit of the photovoltaic system voltages of up to 50 V may occur You should therefore never touch non isolated conductor ends Use well isolated tools only Do not use measurement equipment you know to be damaged or defective The charge controller s constructive protective measures can deteriorate if the extensi on module is not operated as specified by the manufacturer Factory labels and markings may not be altered removed or rendered unreadable Impeding the factory installed ventilation may result in overheating and failure of the device Do not cover ventilation openings and cooling elements All work must be carried out in accordance with the national and local electrical regulations If the device is installed abroad information on rules and protective measures must be obtained via the corresponding institutions authorities Keep children away from the PV system 1 3 About this manual This manual describes the functions and installation of a solar charge controller in a PV system with battery bank The corresponding manufacturer s installation manual must be observed when installing the remaining components e g solar modules and battery bank Before you start work please read e Assembling the charge controller
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