Steca Power Tarom 2070, Power Tarom 2140, Power Tarom 4055, Power Tarom 4140, Power Tarom 4110 Installation And Operation Instruction Manual

Installation and Operation Instruction Manual

System Manager for Photovoltaic systemes

Power Tarom

Tarom 2070, Tarom 2140, Tarom 4055, Tarom 4110, Tarom 4140

09.47

PHOTOVOLTAIK - PHOTOVOLTAIC - PHOTOVOLTAIQUE - FOTOVOLTAICA

EN

Power Tarom Manual

1 SAFETY INSTRUCTIONS AND WAIVER OF LIABILITY...................................................................................... 3

1.1 SYMBOL OF SAFETY INSTRUCTIONS.............................................................................................................................. 3

1.2 HOW TO USE THIS MANUAL......................................................................................................................................... 3

1.3 GENERAL SAFETY INSTRUCTIONS................................................................................................................................. 3

1.4 WAIVER OF LIABILITY.................................................................................................................................................. 4

2 QUICK INSTALLATION INSTRUCTIONS................................................................................................................4

3 APPLICATION RANGE.................................................................................................................................................5

3.1 POWER RANGE ..............................................................................................................................................................5

3.2 OPTIONS ....................................................................................................................................................................... 5

4 FUNCTIONING................................................................................................................................................................ 7

4.1 GENERAL DESCRIPTION................................................................................................................................................ 7

4.2 DETAILED DESCRIPTION ...............................................................................................................................................8

5 INDICATION OF STATUS........................................................................................................................................... 10

5.1 LC-DISPLAY............................................................................................................................................................... 10

5.2 ALARM CONTACT........................................................................................................................................................ 11

6 OPERATING THE SYSTEM-MANAGER ................................................................................................................. 11

6.1 FACTORY PRE-SET CONFIGURATIONS......................................................................................................................... 11

6.2 MAIN MENU ............................................................................................................................................................... 12

6.3 MENU MANU ............................................................................................................................................................ 12

6.4 MENU LOGG ............................................................................................................................................................. 13

6.5 MENU CONF.............................................................................................................................................................. 13

6.6 MENU PROG.............................................................................................................................................................. 14

6.7 EXAMPLE OF CONFIGURATION ...................................................................................................................................17

6.8 EXAMPLE OF PROGRAMMING .....................................................................................................................................18

7 INSTALLATION............................................................................................................................................................ 18

7.1 PRECAUTIONS .............................................................................................................................................................18

7.2 LOCATION OF INSTALLATION .....................................................................................................................................18

7.3 PREPARATIONS ........................................................................................................................................................... 19

7.4 INSTALLATION AND OPERATION.................................................................................................................................. 20

7.5 UNINSTALLING ........................................................................................................................................................... 21

7.6 SAFETY MEASURES ..................................................................................................................................................... 21

8 OVERVOLTAGE PROTECTION IN YOUR PHOTOVOLTAIC SYSTEM.......................................................... 22

9 GROUNDING.................................................................................................................................................................23

9.1 POSITIVE GROUNDING................................................................................................................................................. 23

9.2 NEGATIVE GROUNDING............................................................................................................................................... 23

10 HINTS FOR THE USAGE OF MULTIPLE POWERTAROMS........................................................................... 24

11 MAINTENANCE ........................................................................................................................................................ 25

12 TECHNICAL DATA................................................................................................................................................... 25

12.1 PERFORMANCE DATA .............................................................................................................................................. 25

12.2 REGULATION DATA.................................................................................................................................................. 25

13 MALFUNCTIONS AND ERRORS........................................................................................................................... 26

14 LEGAL GUARANTEE............................................................................................................................................... 27

15 ACCESSORIES........................................................................................................................................................... 27

2

1 Safety Instructions And Waiver of Liability

1.1 Symbol of Safety Instructions

Safety instructions for personal protection and instructions that refer to the safety functions of the
system are marked with this sign and are printed in bold letters.

For safe installation of other components which are not mentioned in the PV System-Manager
instructions, please see the corresponding safety manual of the component manufacturer.

1.2 How To Use This Manual

This manual describes the functions and installation of a PV System-Manager - a solar charge/load
controller in a PV system with a battery as storage.

For safe installation of other components, e.g. solar modules, electrical accessories and battery, please
see the corresponding manual of the manufacturer.

Hint: Before you start your work, read the instructions for Installation (chapter 7; page 18). Make sure that

all preparatory measures are taken.

Only start to install the System-Manager when you are sure that you have understood all the technical
details of this manual. Please make sure that all steps are done in the sequence that is described in this
manual.

These instructions must be handed out to all persons that work with this system. These instructions are
part of the System-Manager and must be handed over in case the System-Manager is sold.

This manual has to be made accessible for any third party or parties working on the PV system.

Before you start work:

• Read the chapter Installation (chapter 7; page 18)

• Make sure that all Precautions (chapter 7.1; page 18) are taken.

• Only start to install your System-Manager when you are sure that you have understood all

instructions.

• Only proceed in the order started in this manual!

1.3 General Safety Instructions

For your own safety, please note the following for installation:

Avoid generating sparks!

Solar modules produce current whenever light strikes them. Even at a small light level, the full voltage can
be present. Therefore, work carefully and pay attention to the corresponding safety precautions.
Disconnect the modules with separate circuit breakers while connecting the system.

During installation and wiring of the photovoltaic system, the system voltage may double (with the 12 V
system up to 24 V, with the 24 V system up to 48 V, and within the 48 V system up to 96 V)

Never touch bare wire ends even in DC Systems! This habit can cause injury or even death!

Only use well insulated tools!

Do not use technical tools that are defective or broken!

The safety features of the System-Manager can be defeated when it is operated in a way not specified by
the manufacturer.

Restriction of ventilation can lead to overheating of the System-Manager and thus failure. Do not cover
any ventilating slots or cooling ribs.

The System-Manager must not be installed and used in moist damp areas (e. g. bathrooms) or in rooms
in which there are flammable gas mixtures (from gas bottles, paint, solvents etc.)!

Do not allow anyone to store any of the above-mentioned hazardous items, or similar items in rooms
where the System-Manager is installed!

3

The pre-set signs and marks must not be changed, removed, or made illegible.

All operations must be conducted in accordance with your national electricity regulations and local rules!

For installation in your country, please see your corresponding institutions for information on regulations
and safety measures.

Keep children away from any and all electronics! Fatal accidents can occur!

1.4 Waiver Of Liability

The manufacturer (STECA and its assigned representatives) cannot check that this manual is strictly
followed, nor the conditions and methods for installation, operation, use and maintenance of the System­Manager.

Improper installation can lead to physical damage to the System-Manager and its safety features, and
thus can endanger persons.

Therefore, we the manufacturer do not take any liability and responsibility for losses, damages and costs
which are due to an improper installation, operation, use and maintenance or any other consequences
resulting from such damage.

Furthermore, we do not take any liability for infringements of patent rights, or rights of third persons, which
result from the use of this System-Manager.

The manufacturer reserves the right to make alterations, without prior notice, to the product itself,
technical data or the installation and instruction manual.

If other components, which are not prescribed by manufacturer are connected to this System-Manager,
the user has to accept the consequences.

2 Quick installation instructions

Please do all steps following the numbers below. Do not go ahead if any step failed.

1. Check system parameters and PowerTarom label : System voltage, max. module/load current

2. The solar modules have to be equipped with an extra switch or circuit breaker (CB).

3. fix the PowerTarom vertically at the wall

4. Switch off battery, modules and load:
a. switch off external battery fuse or CB and the main CB inside the PowerTarom
b. switch off the modules at the external module CB
c. switch off all loads

5. cabling (not yet to be switched on)
a. connect the battery poles to the A+ and A (blue) terminals. Respect polarity!
b. connect the modules to the M+ and M (blue) terminals. Respect polarity!
c. connect the load to the L+ and L (blue) terminals. Respect polarity!

6. switch on battery
a. switch on battery CB (external and in the PowerTarom). Do not switch on the modules yet.
b. watch the LC-display for proper indication of system voltage

7. switch on the modules
a. switch on the external module CB
b. watch the LC-display for proper indication: during daylight you should see the module currents,

“I mod” and “I in”

8. switch on the load
a. switch on the load and check whether the load is working
b. watch the LC-display for proper indication of the load current (top-rightmost number).

9. installation is completed, congratulations. Check these chapters, too:
a. over voltage protection, part 8.
b. multiple controllers working together, part 10 if more than one controller charge the same battery .

4

trouble shooting

ad 6.) LC-Display not working: battery fuse ok? cabling ok? polarity ok? check battery voltage at A+ and
A−terminal ? display plug loose? Press the three left buttons ▴ ▾ ok simultaneously to restart the display.

ad 7) no module current: polarity ok? module connection ok (parallel/serial)? check module voltage
outside the PowerTarom? solar radiation high enough?

ad 8.) load not working: “deep protection” active ? polarity ok? load fuses ok?

If you do not have external module switches you have to connect the battery first and then the module
input to support the automatic voltage identification in 12/24V systems.

3 Application range

The system controller can be used in PV energy supplies with battery storage within the field of business
and commerce as well as in firms and telecommunication devices.

Although the case is IP65 waterproofed it should be protected against heavy rain or direct sun.
In order to keep the voltage drop between controller and battery to a minimum please use only short
battery cables.
To adapt the final charge voltage of the battery for optimal charging the attached temperature sensor
should be mounted next to the battery clamps.

The controller should only be used for regulating solar modules. It regulates the charging current from the
modules using the shunt (short circuit) principle. However, the battery can also be charged by multiple
PowerTaroms or other sources with appropriate battery charge functions.

3.1 Power range

The controller can be used in a wide range of performance and
temperature. It automatically registers the maximum permissible
temperature and disconnect the loads in the case it is exceeded.
Now the complete radiating surface of the heat sink could be
used for the power loss produced during charging.

20°

C

5

0

°

C

200

40

100

120

20

40

100

120

Load current

%

M

o

d

u

le

c

u

r

r

e

n

t

Select dimensioning in a way that the ambient temperature line is
not exceeded in the case of maximal charge and discharge
currents. With an ambient temperature of 20 °C and correct
installation the controller can process both module and load
nominal currents (see labels). These nominal currents
correspond to 100 % in the diagram.

3.2 Options

The System-Manager can be operated with the following additional devices which you can purchase at
authorized dealers. The options of description and instructions are pointed out by following listed
possibilities and examples of use:

⇒ External current sensors can be installed in the power

wires of generators or loads that are not being controlled
by the System-Manager directly. This enables the
System-Manager to calculate the state of charge (SOC)
even when external sources like wind or diesel
generators charge the battery, or when bigger loads like
inverters are connected directly to the battery. The
shunts register the current and send the current readings
into the System-Manager digitally.

G

AC

DC

AC

DC

Data

transm ission

• The pair-shunt solution enables separate measurement and indication of charging and
discharging currents. All load and charging currents have to be conducted across either the

charge or discharge current measuring shunt, except for those currents already flowing through the
System-Manager (the System-Manager already measures these currents internally automatically).

5

Please take care, that in this case all additional power sources
must have a voltage limitation to prevent the battery from
being overcharged.

G

AC

DC

AC

DC

Data

transm ission

• A single shunt can be put into the battery cable that
measures the balance between the charging and
discharging currents. This battery current is then displayed.
With this variation, it is also possible calculate the SOC, but
only one single shunt is necessary.

⇒ The included external temperature sensor must be used to tell

the PowerTarom the actual battery temperature. The final charge voltage will then be optimized by a
temperature compensation.

⇒ The System-Manager transmits system parameters via the DC power lines. These parameters can be

evaluated at each point of the DC grid with additional receivers. Using this unique feature, there are
many possibilities such as:

• remote load disconnection with different priorities. Remote control switches are individually
programmed in accordance with the load status at which the corresponding load is switch on or off.
With this feature, the light in a certain room can be
switched off when the System-Manager signals that the
battery is reaching a deep discharge level. However,
emergency lights could be left on (no total darkness!)
until a certain even lower battery level is reached. The
emergency light might consume much less energy, so
that it can be kept for a long period of time.

day: OFF
nigh t: ON

20%: OFF
40%: ON

40%: OFF
70%: ON

• Operating lights during nighttime, e.g. entrance lights. With the help of the module current, the
System-Manager knows the intensity of light outside, so that no additional light sensor is needed.

G

A

C

DC

data

transmission

• PV Array bank switching: With the remote control switch, additional solar modules for charging the
battery can also be used without parallel operation of System-Managers. As soon as the charge
current of the main solar array (connected directly to the System-Manager) is reduced to a
minimum, the second array will be disconnected from the battery by the receiver. (see diagram at
right) In this way, the first array supplies maximum charge current,
(which is necessary to keep up the final charge voltage) and the
battery can be charged according to the desired IE charge
characteristic by simply switching on or off further arrays.

• operation of additional charging sources, e.g. diesel generators,
grid-operated charge devices. These devices are put into operation
at a low state of charge and switched off after recharging the
battery. For most back-up generators, the remote control switch
serves not as a power switch, but as a start signal to start the
generator (only usable for 2-wire start system generators).

• Switching on excess loads: When the final end-of-charge
voltage, is reached, the System-Manager must limit the charge current. During this time, a big
portion of the solar energy is no longer used for charging the battery, and is simply wasted.
However, a diversion load can be switched in by the remote control switch. As soon as there is
excess current, instead of being wasted, it is forwarded to excess load such as heating coils or
electrolyser units to generate hydrogen for fuel.

⇒ An external data

logger can be
connected to the
System-Manager. It
stores essential
system parameters
that can be
forwarded to a PC via a serial interface (optional USB). The Data collection frequency can be chosen
freely to determine the data collection period. An additional analogue input can register external
parameters, that cannot be measured by the System-Manager itself: wind speed, module temperature,
solar radiation, etc. The logger comes with the necessary software to operate all the above features.

internet

• The logger is able to be programmed by the PC

• The logger is available with an integrated cable modem for remote monitoring

6

• Instead of a cable modem you could order a GSM modem as well. With this modem you are

complete independent to any infrastructure

• The TarCom version ETN can be integrated into an Ethernet computer network.

4 Functioning

The System-Manager monitors the charge status of the battery, regulates the charge process as well as it
switches the loads on -off in order to make full use of the battery and to extend its life.

On delivery, the system is set for use with lead accumulators (batteries) with liquid electrolyte and can be
set for accumulators with fixed electrolyte like gel batteries. The System-Manager can be used for all
types of solar modules.

4.1 General Description

The System-Manager is an intelligent System-Manager in which a microprocessor has been employed for
all regulating, controlling and indicating functions. The main power switching components consist of low­loss MOSFET type-transistors that have a long operating life and guarantee high performance due to their
excellent conductivity, thus leading to a low degree of internal heat generation in the System-Manager.
The customer can configure all parameters without opening the System-Manager or adjusting the
electronic components. Due to the unique feature of the System-Manager to send and receive data
transmission via the power cable itself, a minimum number of extra sensor and data cables is required.
The System-Manager is therefore easy to install even for a person without technical education, and errors
caused by defective cables or sensor wires are greatly reduced.

The overcharge protection is accomplished by a pulse-width modulation parallel (shunting type) controller
which is equipped with a MOSFET switch element and with a reverse diode in order to prevent current
flowing back from the battery to the module at night. While following the standard IE curve, the charging
process is also adjusted according to the temperature. Moreover, the history of the battery’s depth of
cycling over the last few days itself also determines a temporary limitation on excess final charge voltage
and also limits the time of boost of equalizing charges. Voltage drops of the battery cabling and
connections and due to the internal resistance of the battery itself are compensated automatically in the
sophisticated patented software inside the System-Manager, without using extra sensor cables.

In order to protect the battery from being totally discharged, the loads are automatically disconnected
from the battery under certain conditions. The System-Manager’s microprocessor determines the
remaining capacity at which no more consumption is possible without damaging the battery and shuts off
the loads if the remaining capacity in the battery falls below this limit. Furthermore, the loads are switched
off in the case of excess current or temperature for the protection of the System-Manager, and in the case
of excess voltage for the protection of the loads, and in the case of low voltage for the protection of the
battery.

The integrated temperature compensated equalisation charge function automatically does preventive
maintenance on the battery from time to time via electrolyte circulation (controlled gassing) and increases
battery life by preventing harmful acid or sulphate layers. This increase in the final charge voltage is time­triggered after the battery has reached a certain level of voltage in normal charging. After this equalisation
charge time is completed, the System-Manager returns to normal charging. In addition, equalisation
charging enables a faster full charging during bad weather periods e.g., in winter, as only part of the
energy is need for gassing, whereas the remaining energy can be used for fast charging. This timed
equalisation charge function is activated by either undershooting of a determined SOC, or by exceeding a
certain period of time after the last equalisation charge. Equalisation charging can also be activated
manually.

An LCD display indicates important information on the current operating status. The first line informs
briefly on the most important basic parameters and the second line displays fine parameters or system
information. This displays are changing their information every three seconds.

The System-Manager has a reverse battery protection and is secure against no-load operation and short
circuit. The load output is protected against over-current. However, it is very likely that the System­Manager is damaged if components are not connected to the correct terminals (e.g. if battery is
connected in reverse polarity to the module input terminals).

7

4.2 Detailed Description

4.2.1 SOC (State Of Charge) Calculation

With the help of a proprietary patented software algorithm, the System-Manager is capable to ”learn“ the
characteristics and parameters of the battery. This SOC reading is very accurate and therefore is the
basis for most controlling and monitoring functions. However, if system components are directly
connected to the battery, the state of charge can only be determined with the help of the optional current
sensors HS200. The state of charge always refers to the actual capacity which the battery has in
accordance to its age. So a SOC of 50 % does not mean that half of the battery’s nominal rated capacity
can be used, but that only half of the battery’s REAL MEASURED capacity is remaining.

The state of charge is not dependant on the battery voltage, but on the amount of energy taken out.
Traditional controllers usually determine a final load voltage that hardly ever corresponds to the discharge
depth. During discharge, nominal acid density is being reduced and sulphates are placed on the battery
plates. If discharge is too deep, this growth leads to harmful sulphatation that reduces the battery’s
capacity considerably, thus making the battery useless for energy storage. The traditional measuring
procedures (Ah balancing, acid density measuring) are time-consuming and cost intensive and are
seldom integrated in charge controllers.

If generators or loads are directly connected to the battery without current sensor HS200, the SOC gets
“tricked” and its determination is wrong. However, despite erroneously measured SOC values., the
System-Manager still prevents the battery from falling below certain voltage values, in order to protect the
battery from a too-deep damaging discharge

The System-Manager is able to convert to a voltage regulation mode (chapter

6.5, page 13). Now
System-Manager will operate like a conventional charge controller. We recommend this conversion when
using additional generators (diesel, wind, etc.) or loads which are connected direct to the battery (inverter,
etc.). See for option 2.2 current sensor HS200, too.

4.2.2 Overcharge Protection

The overcharge protection prevents uncontrolled gassing within the battery cells. The gas development is
depending on the acid temperature and cell voltage. So the System-Manager monitors the ambient
temperatures and adjusts the battery’s maximum allowed charge
voltage. The overcharge protection and voltage limitation is
independent on the battery’s state of charge, since the
decomposition of electrolyte is exclusively depending on the voltage
and the temperature. This means that charging is already limited
even though the battery is not completely charged.

Overcharging the battery leads to uncontrolled gassing. Here the
electrolyte is decomposed into oxygen and hydrogen. The
consequences are harmful oxidation processes and mechanical
damages since the gas blisters may knock out active lead material
from the lead plates.

What is even worse is that the uncontrolled gassing in closed
batteries e. g. sealed or fluid batteries where the gas pressure can
even burst or crack the battery case. Frequent overcharging damages the battery casing. The charging
process and the overcharge protection are thus regulated by a new hybrid System-Manager utilizing
pulse width modulation in order to insure smooth battery charging. The user in particular should not
choose a float voltage too high via user settings. If you want to program this value individually from the
System-Manager’s factory setting, please take note of the battery manufacturers' recommendations.

-20

-40

-10

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2,20

2,25

2,30

2,35

2,40

2,45

2,50

2,55

2,60

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13,5

13,8

14,1

14,4

14,7

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4.2.3

Temperature Compensation Of Final Charge Voltage

As the battery temperature increases, the acid/lead battery’s optimal final load voltage decreases. A
constant final charge voltage leads to uncontrolled gassing in the case of higher battery temperatures,
and undercharging in case of low temperatures. The temperature compensation software algorithm
automatically decreases the final charge voltage at higher temperatures and increases them at lower
ones. The temperature compensation system with the sensor integrated in the System-Manager
influences all three overcharge thresholds.

• The attached external battery temperature sensor should therefore be mounted next to the battery to

determine the exact temperature.

8

4.2.4 Voltage Determination

Due to a special measuring method, battery sensor wires are no longer needed. The drop in voltage on
the battery cable is compensated after the first full charge process. This is why no further sensor or wiring
is needed, the installation is simplified, and the reliability of the system is increased due to the fact that
sensors and wiring cannot break. However, measurements may not be as precise as with sensor wires.
We would like to mention that – for a temperature coefficient factor of approx. 25mV per 1°C (changing of
the final charge voltage with the ambient temperature within the 12V system) – a tolerance of 100mV
corresponds to a temperature deviation of 4°C. There are no negative influences on the battery charging
curves with such low deviations.

4.2.5 Energy Determination

The energy determination (SOC and Current readings) are calibrated on the lower energy range so within
the maximum currents possible there may be deviations from an accurate electronic test meter. Please
remember that this System-Manager is not a measuring device, but we have put these indications for
your convenience.

4.2.6 Boost Charging (Lead&Sealed) And Equalisation Charging (Only Lead)

For this charging cycle, the System-Manager increases the battery charge voltage for a certain period of
time after the battery has fallen below a certain SOC. The Boost Charge countdown is only activated
when the desired battery voltage has been reached. This is the reason why it is important to pay attention
to the fact that the solar module will be able give out sufficient charge energy with the corresponding final
voltages.

You can manually activate the time limited boost charging.

If the Boost Charge voltage level is too high in comparison with the module voltage (reduced by wire
losses) the countdown may never be started and your battery is therefore charged at a higher

voltage with no time control.

Equalizing charge works similar to the above Boost Charging but is at an even higher voltage. Using
equalisation charging is only possible and can only then be programmed if the battery has been
configured to be of liquid electrolyte type. It is activated when the battery falls below a certain SOC status

4.2.7 Automatic Monthly Mixture Of Electrolyte

Batteries that are shallow cycled will never trigger the equalisation cycle, so an automatic function has
been added so the final charge voltage is increased for a limited time every month. In this case, either
Boost or Equalise charging is activated depending on the electrolyte configuration. This function prevents
harmful acid layering which occurs especially after remaining a long time at a certain charge status.

4.2.8 Display

A double-line liquid crystal display (LCD) informs the user about important system parameters using
various digital readouts. The first line of the LCD indicates SOC, battery voltage, load current and
charging current in approximated “rough” values.
The second line scrolls through various information and system parameters and current status with more
detailed values and descriptions.
The LCD works correctly only within the operating temperature range specified by the manufacturer.
When this temperature range is exceeded, disturbances may occur which prevent reading the display.
The display will return to normal when the operating temperature range is again reached. The storing
temperature range, however, must not be exceeded or permanent damage may occur.

4.2.9 Overdischarge Protection

Overdischarging leads to sulphation and as result a loss of your battery’s capacity. The overdischarge
protection feature disconnects the loads if the battery is becoming too discharged and re-connects them
after sufficient re-charging. The loads can also be manually switched on/off, so the System-Manager can
be used as a main DC load disconnect switch.
If the battery voltage falls under a certain voltage, the loads will be switched off, regardless of whatever
values or manual adjustments have been programmed. (emergency cut-off)

The System-Manager is able to be converted into voltage regulation. After this configuration all values are
able to program with voltage values. The discharge protection is now based on voltage and no longer on
SOC which represent the acid density much better than voltage levels.

9