Steca Solarix 2401, Solarix 4401 User Manual

Solar Charge Controllers

128

187

4985

177

4x ø5

Steca Solarix

2401, 4401

The solar charge controllers Steca Solarix 2401 and 4401 are optimally suited for inverter systems. The controller combines basic solar charger functions with a 40 A high-performance charge controller. It is available as 12 V / 24 V and 48 V system. This makes the solar charge controller very cost effective.

The load current is limited to 10 A. The charging processes are based on the voltage level, which can be individually set with the help of four buttons behind the front casing.

Product features

 Hybrid controller

 Voltage regulation

 Automatic detection of voltage

 PWM control

 Multistage charging technology

 Load disconnection depending on voltage

 Automatic load reconnection

 Temperature compensation

 Common positive grounding or negative grounding on

one terminal

 Integrated self test

 Monthly maintenance charge

Electronic protection functions

 Overcharge protection

 Deep discharge protection

 Reverse polarity protection of load, module and battery

 Reverse polarity protection by internal fuse

 Automatic electronic fuse

 Short circuit protection of load and module

 Overvoltage protection at module input

 Open circuit protection without battery

 Reverse current protection at night

 Overtemperature and overload protection

 Battery overvoltage shutdown

Displays

 Text LCD display

— for operating parameters, fault messages, self test

Operation

 Simple menu-driven operation

 Programming by buttons

 Manual load switch

Interfaces

 RJ45 interface

Options

 External temperature sensor

 Alarm contact

Certificates

 Compliant with European Standards (CE)

 Made in Germany

 Developed in Germany

 Manufactured according to ISO 9001 and ISO 14001

[40 A]

[areas of application]

1920 W

2401 4401

Characterisation of the operating performance

System voltage 12 V (24 V) 48 V

Own consumption 14 mA

DC input side

Module current 40 A

DC output side

Load current 10 A

End of charge voltage 13.7 V (27.4 V) 54.8 V

Boost charge voltage 14.4 V (28.8 V) 57.6 V

Equalisation charge 14.7 V (29.4 V) 58.8 V

Reconnection voltage (LVR) 12.6 V (25.2 V) 50.4 V

Deep discharge protection (LVD) 11.1 V (22.2 V) 44.4 V

Operating conditions

Ambient temperature -10 °C … +60 °C

Fitting and construction

Terminal (fine / single wire) 16 mm

/ 25 mm2 - AWG 6 / 4

Degree of protection IP 32

Dimensions (X x Y x Z) 187 x 128 x 49 mm

Weight 550 g

Technical data at 25 °C / 77 °F

programmable

Steca PA TSK10 External temperature sensor

User- and Operation manual

Specially designed for hybrid systems and telecommunications

Steca Solarix 2401 - 4401

716.148 | Z02 | 09_45

PHOTOVOLTAIK - PHOTOVOLTAIC - PHOTOVOLTAIQUE - FOTOVOLTAICA

System-Manager TAROM | 716148 page 2 V09_45A

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 Range of Applications...........................................................................................................................................4

2.1 Performance............................................................................................................................................................5

3 Functioning ............................................................................................................................................................5

3.1 Description...............................................................................................................................................................5

3.1.1 Overcharge Protection..............................................................................................................................................................5

3.1.2 Temperature Compensation Of Final Charge Voltage...............................................................................................................6

3.1.3 Boost Charging (Lead&Sealed) And Equalisation Charging (Only Lead)..................................................................................6

3.1.4 Automatic Monthly Mixture Of Electrolyte..................................................................................................................................6

3.1.5 Display......................................................................................................................................................................................6

3.1.6 Overdischarge Protection..........................................................................................................................................................6

3.1.7 Control Keyboard......................................................................................................................................................................7

3.1.8 System Voltage.........................................................................................................................................................................7

4 Indication Of Status...............................................................................................................................................7

5 Operating The System-Manager...........................................................................................................................8

5.1 Safety Cover............................................................................................................................................................8

5.2 Main Menu...............................................................................................................................................................8

5.3 Sub Menu ................................................................................................................................................................8

6 Installation............................................................................................................................................................10

6.1 Precautions............................................................................................................................................................10

6.2 Location Of Installation..........................................................................................................................................10

6.2.1 Installation On Walls ...............................................................................................................................................................11

6 2.2 Rules for mounting the System-Manager................................................................................................................................11 .

6.3 Preparations ..........................................................................................................................................................11

6.3.1 Assemblies..............................................................................................................................................................................11

6.3.2 Preparation Of Wiring..............................................................................................................................................................11

6 3.3 Cabling.................................................................................................................................................................................... 11 .

6.4 Installation And Operation .....................................................................................................................................12

6.4.1 Connecting The Battery Bank To The System-Manager.........................................................................................................12

6.4.2 Connecting The Solar PV Module Array To The System-Manager .........................................................................................12

6 4.3 Connecting The Loads............................................................................................................................................................ 12 .

6.5 Uninstalling............................................................................................................................................................13

6.6 Safety Measures....................................................................................................................................................13

6.6.1 Electronic Short Circuit Safety.................................................................................................................................................13

6.6.2 Hardware Safety.....................................................................................................................................................................13

6.6.3 Flammability............................................................................................................................................................................13

6.6.4 Overvoltage Protection............................................................................................................................................................13

6 6.5 Simple And Double Errors.......................................................................................................................................................13 .

6.7 Grounding..............................................................................................................................................................14

6.7.1 Positive Grounding..................................................................................................................................................................14

6.7.2 Negative Grounding................................................................................................................................................................14

7 Maintenance.........................................................................................................................................................14

8 Technical Data .....................................................................................................................................................14

8.1 Performance Data..................................................................................................................................................14

8.2 Controlling Data at 25°C........................................................................................................................................15

9 Malfunctions And Errors.....................................................................................................................................15

10 Legal Guarantee...................................................................................................................................................16

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 6; page 10). 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 6; page 10)

• Make sure that all Precautions (chapter 6.1; page 10) are taken.

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

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. Cover the modules with something to block the light 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)

Therefore: Do not ever 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.)!

System-Manager TAROM | 716148 page 3 V09_45A

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

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 System-Manager.

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.

CAUTION: Opening the System-Manager (connecting cover excluded) as well as use other than prescribed by the manufacturer, will cause the warranty to be voided.

2 Range of Applications

The System-Manager is designed for a wide range of applications from private use to professional use: private homes or leisure market (like recreational vehicles or weekend/seasonal cottages, etc.) or in locations where trade, business or commerce is done (like workshops, stores, offices etc.) or industrial applications or telecom systems.

The System-Manager can NOT be used outdoors, where it would not be protected against rain or sun. Unless external temperature sensor the System-Manager must be installed in the same room as the battery due to the

following reasons:

• an integrated temperature sensor registers the ambient temperature of the room, which is almost identical to the battery temperature.

• In order to keep the voltage drop between System-Manager and battery to a minimum, please only use the shortest possible battery cables.

The System-Manager’s PV input should only be connected to solar modules. However, the battery can also be charged in parallel by other sources with appropriate battery charge functions.

Hint: The System-Manager is able to adapt to customised applications. We will optimise your product concerning your

special requirements. With these modifications the System-Manager will withstand strong ambient conditions like advanced temperature range, mechanical and climatic ambient conditions or advanced interference resistance.

System-Manager TAROM | 716148 page 4 V09_45A

2.1 Performance

The System-Manager uses a heat sink (the black aluminium back plate) to dissipate heat produced by the electronics during high amperage charging. The SystemManager can be used in a wide range of conditions and temperatures. It automatically detects the maximum permissible temperature of the heat sink and disconnects the loads in the case that temperature is exceeded. Therefore, the heat sink can be shared for the heat produced during charging and powering the loads. However, it is necessary to stay within the “Safe Operating ARea“ (SOAR) for sizing the system in order to avoid undesired switch-off of the loads in the case the temperature is exceeded.

You must size the PV system 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 System- Manager can handle both 100% module and 100% load nominal currents (see graph at right). These nominal currents correspond to 100 % in the diagram

nominal load current / A

nominal module current / A

Hint: If you install the System-Manager into an electrical box or cabinet enclosure, please assume the maximum

temperatures inside this box. These are higher than the ambient temperatures, since the System-Manager and other devices may well increase the temperature.

3 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.

3.1 Description

3.1.1 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 utilising 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.

System-Manager TAROM | 716148 page 5 V09_45A

3.1.2 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 integrated sensor makes maintenance and installation easier and can be properly used under the following circumstances:

• System-Manager and battery must be in the same room

-20

-40

-10

-14-0321050206830864010450122

13,2

13,5

13,8

14,1

14,4

14,7

15,0

[°C] [°F]

2,20

2,25

2,30

2,35

2,40

2,45

2,50

[°C] [°F]

2,35

2,40

2,45

2,55

• the System-Manager’s own warming-up is compensated by substantial calculations. However, even if the sensor was outside the SystemManager, the room temperature itself only corresponds to the battery pole temperature, so actual electrolyte temperature inside the battery may be actually different by a bigger margin of error.

• However, an external sensor can be installed if the most accurate sensing is desired.

3.1.3 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 voltage. 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.

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.

Equalising 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 voltage

3.1.4 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.

3.1.5 Display The display scrolls every 3

second. Pressing once the OK button stops the scrolling at the actuell window. Pressing this key will start the scrolling again. 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.

3.1.6 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.

System-Manager TAROM | 716148 page 6 V09_45A

+ 14 hidden pages

Steca Solarix 2401, Solarix 4401 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual