Steca PL2085 Use and care manual

User´s and Installer´s Manual
Charging Station for Photovoltaic Systems
PL2085
704.937 | 07.50
PHOTOVOLTAIK - PHOTOVOLTAIC - PHOTOVOLTAIQUE - FOTOVOLTAICA
EN

Operating instructions PL2085 charging station Page 2 10.12.2007
1Safety instructions and liability exclusion........................................................................................................................................3
1.1 Identification of safety instructions................................................................................................................................................3
1.2 About this manual.........................................................................................................................................................................3
1.3 General safety instructions...........................................................................................................................................................3
1.4 Liability exclusion..........................................................................................................................................................................4
2Description of operation.....................................................................................................................................................................4
2.1 General description.......................................................................................................................................................................4
2.2 Detailed description......................................................................................................................................................................4
2.2.1 Overcharge protection........................................................................................................................................................................................... 4
2.2.2 Cut-off voltage temperature tracking..................................................................................................................................................................... 5
2.2.3 Cocedures............................................................................................................................................................................................. 5harging pr
2.2.3.1 Charging an intact battery............................................................................................................................................................................ 5
2.2.3.2 Charging a previously damaged battery....................................................................................................................................................... 6
2.2.3.3 Charging the wrong type of battery (e.g. 6 V) or a battery with cell closure.................................................................................................. 6
2.2.4 Economy mode (Slow Down Mode)...................................................................................................................................................................... 6
2.2.5 Charging in order of priority................................................................................................................................................................................... 6
2.2.6 Ampere hour meter............................................................................................................................................................................................... 6
2.2.7 Rotary switch ........................................................................................................................................................................................................ 6
2.2.8 Display.................................................................................................................................................................................................................. 7
2.2.9 System voltage...................................................................................................................................................................................................... 7
3Installation ...........................................................................................................................................................................................7
3.1 Precautionary measures...............................................................................................................................................................7
3.2 Choice of location for installation..................................................................................................................................................7
3.2.1 Wall mounting ....................................................................................................................................................................................................... 8
3 2.2 Fixing the charging station .................................................................................................................................................................................... 8.
3.3 Cabling..........................................................................................................................................................................................8
3.3.1 General points....................................................................................................................................................................................................... 8
3.3.2 Cables required..................................................................................................................................................................................................... 8
3.3.3 Preparation ........................................................................................................................................................................................................... 8
3.3.4 Connecting the cables to the charging station....................................................................................................................................................... 9
3 3.5 Removal................................................................................................................................................................................................................ 9.
3.4 Safety measures...........................................................................................................................................................................9
3.4.1 Flammability.......................................................................................................................................................................................................... 9
3.4.2 Precision protection against surge voltage............................................................................................................................................................ 9
3.4.3 Single and double errors....................................................................................................................................................................................... 9
4Charging station operation ..............................................................................................................................................................10
4.1 Display and rotary switch............................................................................................................................................................10
4.1.1 Description of first line of the display................................................................................................................................................................... 10
4 1.2 Description of second line of display................................................................................................................................................................... 10.
4.2 Sequence of operation................................................................................................................................................................11
5Maintenance.......................................................................................................................................................................................12
6Technical data at 20°C......................................................................................................................................................................12
7Malfunctions and fault finding .........................................................................................................................................................12
8Legal Guarantee................................................................................................................................................................................13

1 Safety instructions and liability exclusion
1.1 Identification of safety instructions
In this manual safety instructions for personal security are identified by this symbol and are in bold type.
Information concerning the operational security of the equipment is in bold type.
The manufacturer’s safety instructions for additional components you may connect to this charging station must be
observed and are not cancelled by these instructions. In the event of any contradictions between different sets of
instructions please contact the specialist supplier.
1.2 About this manual
This manual describes the operation and installation of a charging station for photovoltaic solar units intended for feeding
solar electricity into lead storage batteries
The relevant manufacturer’s installation instructions must be observed for installing the solar cells and setting up the
batteries.
Tip: Before starting work please read the section entitled Installation (Chapter 3; page 7). Ensure that all preparatory
measures have been taken before installation.
Do not start installing the equipment until you are certain that you have understood the technical instructions and only
carry out the work in the order specified in this manual!
The manual must be available, to third parties as well, during all work that is carried out on the system.
This manual is an integral part of the charging station and must be handed over when the station is disposed of.
1.3 General safety instructions
For your safety it is imperative that you observe the following instructions during installation:
Avoid sparking during all work!
Photovoltaic modules generate electricity when they admit light. The voltage is at its full level even with a low incidence
of light, so exercise care when working and take appropriate safety precautions.
Voltages as high as double the system voltages, that is up to 48V, can occur during assembly and electrical installation in
the photovoltaic system’s direct current circuit.
Therefore: never touch bare lead ends!
Only use properly insulated tools!
Do not use any measuring equipment you know to be damaged or defective!
The safety control inherent in the design of the charging station can deteriorate if it is operated in a manner not specified
by the manufacturer.
Obstruction of the equipment ventilation can lead to overheating and thence to breakdown of the equipment. Do not
cover ventilation openings and heat dissipators.
The charging station is only suitable for indoor use, where it is protected from the effects of the weather such as rain and
direct sunlight. It must not be installed and operated in damp areas (e.g. bathrooms), or in rooms in which easily
combustible gas mixtures can occur, such as from gas bottles, paints, varnishes, solvents, etc!
Do not store any of the above-named materials in rooms where the charging station is installed!
The notices and markings placed on the equipment at the factory must not be altered, removed or rendered
indecipherable.
All work must be carried out in accordance with the national electrical requirements and the appropriate local regulations!
Where the equipment is installed abroad information must be obtained from the relevant institutions or authorities
concerning regulations and safety control.
Keep children away from the control electronics and the battery area!
Operating instructions PL2085 charging station Page 3 10.12.2007

1.4 Liability exclusion
We cannot accept responsibility for damage caused by disregarding these instructions. This also applies to the vicinity of
the charging station and even if the damage occurs as a result of malfunctions of the charging station caused by incorrect
installation.
The manufacturer cannot be responsible for supervising compliance with these instructions or monitoring conditions and
methods employed during the installation, operation, use and maintenance of the charging station.
Incorrect installation can lead to damage to property and consequently can endanger persons. Such damage is the
responsibility of the electrician.
We therefore accept no responsibility or liability for any loss, damage or costs resulting from, or in any way connected
with faulty installation, incorrect operation and incorrect use or maintenance.
We likewise accept no responsibility for violations of patent law or the violation of any other rights of third parties that
result from the use of this charging station.
The manufacturer reserves the right to make modifications regarding the product, technical data and assembly and
operating instructions without giving prior notice.
The use of the charging station in areas of application not defined by the manufacturer is the responsibility of the user.
Caution: The guarantee will be invalidated if the equipment is opened or operated in any way
that does not comply with the regulations.
2 Description of operation
The charging station controls the charging process of up to 8 batteries simultaneously, during which the batteries are fully
charged as economically as possible.
The charging station is designed for batteries such as lead storage batteries with liquid electrolyte and with solid
electrolyte (e.g. gel and flow batteries).
The charging station can be used for all photovoltaic modules.
2.1 General description
An intelligent control unit in which the adjustment, operation and display functions are carried out by a microprocessor, is
an essential part of the 8-battery charging station. The batteries are charged as quickly as possible and also
economically, in order of priority according to when they were connected and using the latest charging process. In
addition an MPP-Tracking system enables optimum use to be made of the energy available. The power components
consist exclusively of low loss MOS-FET transistors with a high switch life, guaranteeing a high level of efficiency through
low power loss.
IU characteristic charging is carried out from a battery voltage of 3V with a cut-off voltage that is dependent on the
temperature. Up to 4 channels can be connected in parallel with a corresponding increase in the charging current.
An LCD display supplies all the important information about the current load of the individual channels. A rotary switch is
used for changing over between individual channels. The charging of all channels can also be interrupted by means of
this rotary switch.
The charging equipment has reverse battery, open circuit and short circuit protection at all inputs and outputs. The
battery output is also protected from overload.
2.2 Detailed description
2.2.1 Overcharge protection
The overcharge protection prevents uncontrolled gassing in the battery cells. The development of gas is dependent on
the temperature of the acid and the cell voltage. The control unit therefore monitors the ambient temperature and adjusts
the battery voltage accordingly. The overcharge protection, and therefore also the voltage limitation, is not dependent on
the charge of the battery, as the dissociation of the electrolytes is only dependent on the voltage and the temperature.
This means that charging is already limited, although the battery is not yet fully charged.
Overcharging of a battery leads to uncontrolled gassing. The electrolyte decomposes into oxygen and hydrogen. This
results in harmful oxidation processes and mechanical damage because the gas bubbles pick up active material from the
lead plates.
The uncontrolled gassing is worse still with closed batteries (e.g. gel and flow batteries) where the resulting gas pressure
can destroy the battery housing. Frequent overcharging damages the battery storage capacity.
Operating instructions PL2085 charging station Page 4 10.12.2007

2.2.2 Cut-off voltage temperature tracking
With lead/acid batteries the optimum cut-off voltage decreases as the
battery temperature increases. A constant setting for the cut-off
voltage leads to uncontrolled gassing at higher battery temperatures.
The temperature tracking lowers the cut-off voltage at high
temperatures and increases it at lower temperatures.
-20
-40 -10 -14 -0 32 10 50 20 68 30 86 40 104 50 122
13,2
13,5
13,8
14,1
14,4
14,7
15,0
15,3
15,6
[°C]
[°F]
2,20
2,25
2,30
2,35
2,40
2,45
2,50
[°C]
[°F]
2,20
2,25
2,30
2,35
2,40
2,45
2,50
2,55
2,60
equalcharge
floatcharge
The temperature is determined by a sensor integrated into the
apparatus and the cut-off voltage is adjusted according to the reading.
The integrated sensor is without maintain, and provided the control
unit and batteries are situated in the same room it can be used
anywhere.
2.2.3 Charging procedures
The following charging characteristics apply to an ambient temperature of 20°C
2.2.3.1 Charging an intact battery
Provided enough energy is available and this battery is next in line as far as priority is concerned, the charging station
starts charging an intact empty battery once it has been connected with up to 5A (first third of the characteristic curve).
On reaching a voltage of 14.3V (at 20°C) the charging station moves into the equal charge phase (second third of the
characteristic curve) in which it raises the cut-off voltage to 14.7V (20°C). After about 2 hours the control system moves
from the equal charge phase into the float charge phase of 13.8V (at 20°C) (third third of the characteristic curve). The
countdown for these 2 hours is only activated when the final charge voltage of 14,7V (at 20°C) can almost be maintained.
During float charging the battery moves to the lowest priority. So the battery voltage can fall below 13.8V in this mode if
too little energy is available. The charging station maintains the battery in float charge until it is disconnected. Thus any
running down of the battery is compensated for.
charge current
charge voltage
14,7 V
13,8 V
5 A
start time
battery capacity
full
empty
90 %
charge (I)
equal charge (U)
float charge (U)
14,3 V
Operating instructions PL2085 charging station Page 5 10.12.2007