Samplex America Solarix MPPT 2010 User manual
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730.97 | 09.10
PHOTOVOLTAIK – PHOTOVOLTAICS – PHOTOVOLTAIQUE – FOTOVOLTAICA
Installation and
operating instructions
Solarchargecontroller
Solarix MPPT 010
730.97 | 09.10
EN
2730.927 | 09.10
Index
1. About these instructions ........................................................................3
1.1 Applicability............................................................................................3
1.2 Users.......................................................................................................3
1.3. Description of symbols ...........................................................................3
2. Safety......................................................................................................3
2.1 Proper usage...........................................................................................3
2.2 Improper usage ......................................................................................3
2.3 General safety instructions .....................................................................4
2.4 Other risks ..............................................................................................4
2.5 Behaviour in the case of faults ...............................................................4
3. Description .............................................................................................5
3.1 Functions................................................................................................5
3.2 Structure.................................................................................................6
3.3 LED displays............................................................................................7
4. Installation..............................................................................................7
4.1. Mounting the solar charge controller.....................................................8
4.2 Connection .............................................................................................8
5. Operation .............................................................................................11
6. Maintenance.........................................................................................12
7. Faults and remedies..............................................................................13
8. Technical data.......................................................................................16
9. Legal guarantee....................................................................................17
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1. About these instructions
These operating instructions are part of the product.
Read these operating instructions carefully before use,
keep them over the entire lifetime of the product,
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. A technical expert
must be consulted in cases of uncertainty.
1.3. Description of symbols
Safety instructions are identified as follows:
SIGNAL WORD
Type, source and consequences of the danger!
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.
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2.3 General safety instructions
Follow the general and national safety and accident prevention regulations.
Never alter or remove the factory plates and identification labels.
Keep children away from PV systems.
Never open the device.
2.4 Other risks
Danger of fire and explosion
Do not use the solar charge controller in dusty environments, in the vicinity
of solvents or where inflammable gases and vapours can occur.
No open fires, flames or sparks in the vicinity of the batteries.
Ensure that the room is adequately ventilated.
Check the charging process regularly.
Follow the charging instructions of the battery manufacturer.
Battery acid
Acid splashes on skin or clothing should be immediately treated with soap
suds and rinsed with plenty of water.
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:
The solar charge controller does not appear to function at all.
The solar charge controller or connected cables are visibly damaged.
Emission of smoke or fluid penetration.
When parts are loose.
In these cases immediately remove the solar charge controller from the bat-
tery and solar module.
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3. Description
3.1 Functions
The solar charge controller
monitors the battery voltage,
controls the charging process,
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 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?
10 20 30 40 50 60 70 80 90 100 110 120
konv. Laderegler
MPPT
UBat
Umpp
Uoc
Solarzellen
10 20 30 40 50 60 70 80 90 100 110 120
konv. Laderegler
MPPT
UBat
Umpp
Uoc
Solarzellen
0
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Number of solar cells
UOC
Umpp
UBat
MPPT
Standard charge
controller
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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 essential 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.
CAUTION
If an 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.
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 II.
3.2 Structure
1
2
345
The solar charge controller consists
of the following components:
Info LED
4 LEDs for displaying the state of
charge (red, yellow, green 1 and
green 2)
Terminal block for connecting
the solar module
Terminal block for connecting
the battery
Terminal block for connecting
the loads
1.
2.
3.
4.
5.
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3.3 LED displays
LED Status Meaning
Info LED illuminates
green normal operation
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
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.
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.
Follow the installation and operating instructions for all components of the
PV system.
Ensure that no cables are damaged.
At a voltage of > 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 II.
Protect the solar modules from incident light during installation, e.g. cover
them.
Never touch uninsulated cable ends.
Use only insulated tools.
Ensure that all loads to be connected are switched off. If necessary, remove
the fuse.
Connections must always be made in the sequence described below (see
4.2.2).
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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.
Do not subject the solar charge controller to direct sunshine or other sources
of heat.
Protect the solar charge controller from dirt and moisture.
Mount upright on the wall (concrete) on a non-flammable substrate.
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
Mark the position of the solar charge controller fastening holes on the wall.
Drill 4 Ø 6 mm holes and insert dowels.
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
18 A 20 A 10 A 10 mm28 85°C
The table above applies to the following cable lengths:
10 m solar module connection cable
2 m 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.
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4.2.2 Connection
213
WARNING
Danger of explosion from sparking! Danger of electric shock!
At a voltage of > 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 II.
1st step: connect the battery
CAUTION
The device will be destroyed if the battery is connected with the wrong polarity.
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 correct, the info LED illuminates green.
If necessary, remove any external fuse.
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2nd step: connect the solar module
CAUTION
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.
Remove the covering from the solar module.
3rd step: connect loads
WARNING
Danger of explosion from sparking! Danger of electric shock!
At a voltage of > 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 II.
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.
Loads with a higher current consumption than the device
output can be directly connected 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).
Label the load connection cables as a plus cable (L+) and a minus cable (L–).
Lay the load connection cables in parallel between the solar charge control-
ler and the load.
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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.
Replace the load fuse or switch on the load.
4th step: final work
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 immediately 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:
protection from solar module short circuits / incorrect solar module polar-
ity
protection from short circuits at the load output or excessive load
current
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protection from solar module overcurrent
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 necessary.
Terminal corrosion
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7. Faults and remedies
Fault Cause Remedy
No display Battery voltage too low• Pre-charge the battery
The external fuse in the
battery connection cable
has blown.
• Replace the external fuse
Battery is not connected• Unclamp all connections
Connect a (new) battery
with the correct polarity
Reconnect the solar module
and loads
1.
2.
3.
Battery is defective•
Battery is connected with
the wrong polarity
• Device may be defective;
Return device to specialist
dealer
Info LED flashes
red Charging interrupted due to
excessive charging current
• Charging automatically
continues as soon as the
charging current lies within
the permissible range
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
+
info LED flashes
red
Load output is switched
off due to excessive load
current
• Reduce load current, if
necessary switch off or
disconnect loads
Check loads
Load output is switched off
due to short circuit at load
output
• Disconnect loads
Correct the cause of the
short circuit
Reconnect loads
1.
2.
3.
Load output is switched off
due to overheating of the
solar charge controller
• The load output automati-
cally switches 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
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Load cannot be
operated
+
info LED flashes
red
+
red battery LED
flashes
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
+
2. green LED
flashes
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
External charging source is
not voltage-limited
• Check the external charging
source
If necessary, switch off
external charging sources
Load cannot be
operated
+
info LED illumi-
nates green
Defective load or installa-
tion error
• Connect load correctly
Replace load
Battery is not
charged Solar module not connected• Connect the solar module
Solar module connected
with incorrect polarity
• Connect the solar module
with the correct polarity
Short circuit at solar module
input
• Correct the cause of the
short circuit
Incorrect solar module
voltage
• Use a solar module of the
specified voltage
Device overheated• Make sure the device is well
ventilated
Solar module defective• Replace the solar module
Battery display
jumps quickly Large pulse current• Tune the current consump-
tion to match the battery
capacity
Battery is defective• Replace the battery
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Efficiency example:
90 %
91 %
92 %
93 %
94 %
95 %
96 %
97 %
98 %
99 %
100 %
400 W320 W280W200 W120 W85 W40 W15 W
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8. Technical data
MPPT 2010
Characterisation of the operating behaviour
System voltage 12 V (24 V)
Rated output 250 W (500 W)
Max. efficiency > 98 %
Own consumption 10 mA
DC input side
MPP voltage 15 V (30 V) < Umodule << 100 V
Open circuit voltage solar module
(at minimum operating temperature) **17 V ... 100 V (34 V ... 100 V)
Module current 18 A
DC output side
Charging current 20 A
Load current 10 A
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) > 50 % / 12.5 V (25.0 V)
Deep discharge protection* (SOC / LVD) < 30 % / 11.5 V (23.0 V)
Application conditions
Ambient temperature -25 °C … +40 °C
Equipment and design
Terminal clamps (fine-wire / single wire) 16 mm2/ 25 mm2- 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
** .
CAUTION
If an 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.
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 II.
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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, excessive 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.
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