Installation and operating instructions EN
Contents
1. A technical expert must be consulted in cases of uncertainty 1 3 Description of symbols Safety instructions are identified as follows A SIGNAL WORD Type source and consequences of the danger gt Measures for avoiding danger Instructions relating to the functional safety of the system are in bold type 2 Safety 2 1 Proper usage The solar charge controller may only be used in PV systems for charging and controlling lead acid batteries with liquid or solid electrolyte in accordance with these operating instructions and the charging specifications of the battery manufacturer 2 2 Improper usage No energy source other than a solar generator may be connected to the solar charge controller No mains devices diesel generators or wind generators may be connected Do not connect any defective or damaged measuring equipment 730 927 09 10 3 2 3 General safety instructions gt Follow the general and national safety and accident prevention regulations gt Never alter or remove the factory plates and identification labels gt Keep children away from PV systems gt Never open the device 2 4 Other risks Danger of fire and explosion gt Do not use the solar charge controller in dusty environments in the vicinity of solvents or where inflammable gases and vapours can occur gt No open fires flames or sparks in the vicinity of the batteries gt Ensure that the room is adequately ventilated2. 10m solar module connection cable e 2m battery connection cable 5 m load connection cable Consult a dealer if the specified cable lengths are inadequate An additional 30 A external fuse not provided must be connected to the battery connection cable close to the battery pole The external fuse prevents dangerous situations due to cable short circuits 8 730 927 09 10 4 2 2 Connection A WARNING Danger of explosion from sparking Danger of electric shock gt Ata voltage of gt 75 V particularly with regard to module open circuit volt age over the entire temperature range the entire solar energy system must be installed with protection class Il 1st step connect the battery A CAUTION gt The device will be destroyed if the battery is connected with the wrong polarity gt Label the battery connection cables as a plus cable A and a minus cable A Lay the battery cables in parallel between the solar charge controller and the battery Connect the battery connection cable with the correct polarity to the middle pair of terminals on the solar charge controller with the battery symbol Connect battery connection cable A to the positive pole of the battery Connect battery connection cable A to the negative pole of the battery If the connection polarity is c
3. C 40 C Equipment and design Terminal clamps fine wire single wire 16 mm 25 mm AWG 6 4 Degree of protection IP 32 Dimensions X x Y x Z 187 x 153 x 68 mm Weight approx 900 g see options Technical data at 25 C 77 F di A CAUTION gt Ifan open circuit voltage of more than 100 V is supplied to the connected solar module the controller will be destroyed When selecting the solar module it is important to bear in mind that the open circuit voltage should never exceed 100 V over the entire working temperature range gt When using solar modules with a maximum open circuit voltage of between 75 and 100 V over the entire temperature range all installation steps must be carried in accordance with protection class Il 16 730 927 09 10 NOTE Technical data that varies from the above is given on a device label Subject to change without notice 9 Legal guarantee In accordance with German statutory regulations there is a 2 year legal guar antee on this product for the customer The seller will remove all manufacturing and material faults that occur in the product during the legal guarantee period and affect the correct functioning of the product Natural wear and tear does not constitute a malfunction No legal guarantee can be offered if the fault can be attributed to third parties unprofessional installation or commissioning incorrect or negligent handling improper transport excessiv
4. LED displays LED Status Meaning Info LED illuminates normal operation green flashes red a fault exists see Faults and remedies Red LED flashes quickly battery empty when the battery continues to be discharged the deep discharge deactivation is triggered flashes deep discharge deactivation Yellow LED illuminates battery weak flashes switch on threshold after deep discharge deacti vation has not yet been reached 1 green LED illuminates battery good 2 green LED illuminates battery full flashes quickly battery full charge regulation active i e charging current reduced 4 Installation A WARNING Danger of explosion from sparking Danger of electric shock Solar modules generate electricity under incident light The full voltage is present even when the incident light levels are low gt The solar charge controller may only be connected to the local loads and the battery by trained personnel and in accordance with the applicable regulations gt Follow the installation and operating instructions for all components of the PV system gt Ensure that no cables are damaged gt Ata voltage of gt 75 V particularly with regard to module open circuit volt age over the entire temperature range the entire solar energy system must be installed with protection class Il gt Protect the solar modules from incident light during installation e g cover them gt Never
5. PHOTOVOLTAIK PHOTOVOLTAICS PHOTOVOLTAIQUE FOTOVOLTAICA Installation and operating instructions Solar charge controller Solarix MPPT 2010 730 927 09 10 Index 1 About these instructions i 3 I CAPI 3 OC EI ERI I 3 13 Description OF Symbols cin e iner enari iiien kian 3 2 E occ A 3 ZE PrOPerusage ti o anat 3 2 2 Improper Usage iii a ll in 3 2 3 General safety instructions 4 2 4 O sila cai A 4 2 5 Behaviour in the case of faults nan nr can nn canos 4 3 Deseription e nn nenn li an 5 al rds A EE a 5 E AAPP aaa 6 33 TED ia A A AAA AAA 7 4 Installation cala ei 7 4 1 Mounting the solar charge controller ii 8 42 COMU 8 bi Operation used tee a ara 11 6 Maintenance 12 de Faults and Ttemedies aura 13 8 Technicalidat iuris sila ia 16 9 Legal gu ra e e 17 2 730 927 09 10 1 About these instructions These operating instructions are part of the product gt Read these operating instructions carefully before use gt keep them over the entire lifetime of the product gt and pass them on to any future owner or user of this product 1 1 Applicability This manual describes the installation function operation and maintenance of the solar charge controller Further technical information is provided in a separate technical manual 1 2 Users These operating instructions are intended for end customers
6. al value for choosing a solar module is the open circuit voltage U_oc The open circuit voltage of the solar module is dependent on the ambi ent temperature Information on the open circuit voltage of the solar module and on temperature dependence can be found in the data sheet of the solar module The lower the ambient temperature the higher the open circuit volt age of the solar module The open circuit voltage at 20 C may not exceed the maximum input voltage A CAUTION gt Ifan open circuit voltage of more than 100 V is supplied to the connected solar module the controller will be destroyed When selecting the solar module it is important to bear in mind that the open circuit voltage should never exceed 100 V over the entire working temperature range gt When using solar modules with a maximum open circuit voltage of between 75 and 100 V over the entire temperature range all installation steps must be carried in accordance with protection class ll 3 2 Structure The solar charge controller consists of the following components Resto 1 Info LED E a 2 4 LEDs for displaying the state of charge red yellow green 1 and green 2 3 Terminal block for connecting the solar module acA o 4 Terminal block for connecting the battery 3 5 5 Terminal block for connecting the loads 6 730 927 09 10 3 3
7. ches on again once the solar charge controller has cooled down Improve the cooling air circulation Remove any other heat sources Check the conditions of use and the mounting location 730 927 09 10 Load cannot be operated info LED flashes red red battery LED flashes e Load output is switched off due to too low battery voltage The load output automati cally switched on again as soon as the battery voltage lies within the permissible range Pre charge the battery Equip loads directly con nected to the battery with deep discharge protection Check the battery and replace if necessary Load cannot be operated info LED flashes red e Load output is switched off due to excessive battery voltage The load output automati cally switched on again as soon as the battery voltage lies within the permissible range e External charging source is not voltage limited Check the external charging source If necessary switch off external charging sources 2 green LED flashes Load cannot be operated info LED illumi nates green Defective load or installa tion error gt Connect load correctly Replace load Battery is not charged e Solar module not connected Connect the solar module e Solar module connected with incorrect polarity Connect the solar module with the correct polarity e Sho
8. e loading use of improper equipment faulty construction work unsuitable construction location or improper operation or use Legal guarantee claims shall only be accepted if notification of the fault is provided immediately after it is discovered Guarantee claims are to be directed to the seller The seller must be informed before guarantee claims are processed For processing a guarantee claim an exact fault description and the invoice delivery note must be provided The seller can choose to fulfil the legal guarantee either by repair or replace ment If the product can neither be repaired nor replaced or if this does not oc cur 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 seller based on this legal 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 730 927 09 10 17 18 730 927 09 10 730 927 09 10 LUI
9. gt Check the charging process regularly gt Follow the charging instructions of the battery manufacturer Battery acid gt Acid splashes on skin or clothing should be immediately treated with soap suds and rinsed with plenty of water gt If acid splashes into the eyes immediately rinse with plenty of water Seek medical advice 2 5 Behaviour in the case of faults Operating the solar charge controller is dangerous in the following situations e The solar charge controller does not appear to function at all e The solar charge controller or connected cables are visibly damaged e Emission of smoke or fluid penetration When parts are loose gt In these cases immediately remove the solar charge controller from the bat tery and solar module 4 730 927 09 10 3 Description 3 1 Functions The solar charge controller e monitors the battery voltage e controls the charging process e controls the connection disconnection of loads connected to the load output This optimises battery use and significantly extends its service life A battery charging algorithm protects the battery from harmful states Activa tion of the three deep discharge functions LVW LVD and LVR is dependent upon the battery voltage 3 1 1 MPP tracking This solar charge controller meets the latest technological standards since it is equipped with an optimal MPP tracking algorithm and thus can use at all times the maximum available output of
10. mmediately begins operation once the battery is connected or the external fuse is inserted The display of the solar charge controller shows the current operating mode User intervention or user settings are not required Protection functions The following integrated protection functions of the solar charge controller ensure that the battery is handled as gently as possible The following protection functions are part of the basic function of the controller overcharge protection deep discharge protection battery undervoltage protection solar module reverse current protection The following installation faults do not destroy the controller After cor recting the fault the device will continue to operate correctly e protection from solar module short circuits incorrect solar module polar ity protection from short circuits at the load output or excessive load current 730 927 09 10 11 protection from solar module overcurrent e protection from device overtemperature protection from overvoltage at the load output protection from the wrong connection sequence 6 Maintenance The solar charge controller is maintenance free All components of the PV system must be checked at least annually according to the specifications of the respective manufacturers Ensure adequate ventilation of the cooling element Check the cable strain relief Check that all cable connections are secure Tighten screws if neces
11. onnected to the battery However the solar charge controller deep discharge protection will no longer intervene Loads connected in this manner must also be separately fused Loads of this type can also be reliably connected via an additional output relay e g Steca PA EV 200 A gt Label the load connection cables as a plus cable L and a minus cable L gt Lay the load connection cables in parallel between the solar charge control ler and the load 10 730 927 09 10 gt First connect the L load cable to the correct pole of the right pair of ter minals on the solar charge controller with the lamp symbol then connect the L cable gt Replace the load fuse or switch on the load Ath step final work gt Fasten all cables with strain relief in the direct vicinity of the solar charge controller clearance of approx 10 cm 4 2 3 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 Con sult the technical manual for more information 4 2 4 Lightning protection In systems subjected to an increased risk of overvoltage damage we recom mend installing additional lightning protection overvoltage protection to reduce dropouts Consult the technical manual for more detailed information 5 Operation The solar charge controller i
12. orrect the info LED illuminates green If necessary remove any external fuse v vvvv 730 927 09 10 9 2nd step connect the solar module A CAUTION gt The connected modules may not exceed an open circuit voltage VOC of 100 V even at extremely low temperatures Ensure that the solar module is protected from incident light Ensure that the solar module does not exceed the maximum permissible input current Label the solar module connection cables as a plus cable M and a minus cable M Lay both solar module connection cables in parallel between the solar mod ule and the solar charge controller First connect the M solar module connection cable to the correct pole of the left pair of terminals on the solar charge controller with the solar module symbol then connect the M cable gt Remove the covering from the solar module v v v vv 3rd step connect loads A WARNING Danger of explosion from sparking Danger of electric shock gt Ata voltage of gt 75 V particularly with regard to module open circuit volt age over the entire temperature range the entire solar energy system must be installed with protection class Il Notes Connect loads that must not be deactivated by the solar charge controller deep discharge protection e g emergency lights or radio connection directly to the battery e Loads with a higher current consumption than the device output can be directly c
13. rt circuit at solar module Correct the cause of the input short circuit Incorrect solar module Use a solar module of the voltage specified voltage e Device overheated Make sure the device is well ventilated e Solar module defective gt Replace the solar module Battery display jumps quickly e Large pulse current gt Tune the current consump tion to match the battery capacity Battery is defective gt Replace the battery 14 730 927 09 10 Efficiency example 100 99 98 97 96 95 94 93 92 91 90 730 927 09 10 40 W 85 W 120 W 200 W 280W 320 W 400 W 8 Technical data Characterisation of the operating behaviour System voltage 12 V 24 V Rated output 250 W 500 W Max efficiency gt 98 Own consumption 10 mA DC input side MPP voltage 15 V 30 V lt Un e lt lt 100 V Open circuit voltage solar module 17 V 100 V 34 V 100 V at minimum operating temperature Module current 18A DC output side Charging current 20A Load current 10A End of charge voltage 13 9 V 27 8 V Boost charge voltage 14 4 V 28 8 V Equalisation charging 14 7 V 29 4 V Reset voltage SOC LVR gt 50 12 5 V 25 0 V Deep discharge protection SOC LVD lt 30 11 5 V 23 0 V Application conditions Ambient temperature 25
14. sary Terminal corrosion vvvvyv 12 730 927 09 10 7 Fault No display Faults and remedies Cause Battery voltage too low Remedy gt Pre charge the battery e The external fuse in the battery connection cable has blown Replace the external fuse Battery is not connected Battery is defective 1 Unclamp all connections 2 Connect a new battery with the correct polarity 3 Reconnect the solar module and loads Battery is connected with the wrong polarity Device may be defective Return device to specialist dealer Info LED flashes red e Charging interrupted due to excessive charging current Charging automatically continues as soon as the charging current lies within the permissible range e Optobus transfer faulty Repeat programming Battery voltage too low Pre charge the battery Battery voltage too high Check installation Load cannot be operated or only for a short time 4 info LED flashes red e Load output is switched off due to excessive load current Reduce load current if necessary switch off or disconnect loads Check loads e Load output is switched off due to short circuit at load output 1 Disconnect loads 2 Correct the cause of the short circuit 3 Reconnect loads e Load output is switched off due to overheating of the solar charge controller The load output automati cally swit
15. the solar module You will find more detailed documentation about MPP tracking in the technical manual which can be ac cessed at www stecasolar com 3 1 2 What is MPP tracking MPPT MPPT stands for Maximum Power Point Tracking This describes a process by means of which the solar module is always operated at the point of maximum possible power Because the point the maximum power can vary depending on the operating mode and the local conditions and because it changes in the course of the day the term tracking is used i e the tracking of this point 3 1 3 When should charge controllers with MPP tracking be used Number of solar cells li il IMM MPPT M Standard charge controller uE T T T T T T T T T T T T T 0 10 20 30 40 50 60 70 80 90 100 110 120 730 927 09 10 Charge controllers with MPP trackers can be used for a wider range of modules than those without MPPT With an MPP tracker one is no longer dependent on the module voltage and string size The module voltage can deviate signifi cantly from the battery voltage 3 1 4 Notes on choosing suitable solar modules This solar charge controller has a maximum input voltage of 100 V If this is exceeded even for a short time by the connected solar module the solar charge controller will be damaged beyond repair and can never be used again This will NOT constitute a guarantee claim the charge controller must then be replaced at the customer s expense The essenti
16. touch uninsulated cable ends gt Use only insulated tools gt Ensure that all loads to be connected are switched off If necessary remove the fuse gt Connections must always be made in the sequence described below see 4 2 2 730 927 09 10 7 4 1 Mounting the solar charge controller 4 1 1 Mounting location requirements Do not mount the solar charge controller outdoors or in wet rooms e Do not subject the solar charge controller to direct sunshine or other sources of heat e Protect the solar charge controller from dirt and moisture e Mount upright on the wall concrete on a non flammable substrate e Maintain a minimum clearance of 10 cm below and around the device to ensure unhindered air circulation Mount the solar charge controller as close as possible to the batteries with a safety clearance of at least 30 cm 4 1 2 Fastening the solar charge controller gt Mark the position of the solar charge controller fastening holes on the wall gt Drill 4 6 mm holes and insert dowels gt Fasten the solar charge controller to the wall with the cable openings facing downwards using 4 oval head screws M4x40 DIN 7996 4 2 Connection 4 2 1 Preparing the wiring The cross section of the connection cables must be suitable for the currents which occur Modulstrom Batteriestrom Laststrom Querschnitt AWG Isolation 18A 20A 10A 10 mm 8 85 C The table above applies to the following cable lengths e
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