Steca PR 2020 IP65 User manual

Operating instructions
Solar Charge Controller
PR 2020 IP65
Version 2.0
718.573 | Z04 | 11.27
PHOTOVOLTAIK - PHOTOVOLTAIC - PHOTOVOLTAIQUE - FOTOVOLTAICA
EN

2718.573 | 11.27
Subject to change without prior notice!
Contents
1. Safety instructions and liability disclaimer......................................................3
1.1. The safety instructions are marked as follows.......................................................3
1.2. General Safety Instructions ...................................................................................3
1.3. Scope of Application........................................................................................4
1.4. Liability Disclaimer ................................................................................................5
2. Installation .......................................................................................................6
2.1. Installation Site ....................................................................................................6
2.2. Connecting the Regulator ....................................................................................7
2.3. Grounding ............................................................................................................7
3. Protective functions of the controller ............................................................8
4. Operating the system regulator ......................................................................9
4.1. Display and Operation Elements...........................................................................9
4.2. Display Window....................................................................................................9
4.2.1. SOC Window ......................................................................................................10
4.2.2. Voltage window .................................................................................................10
4.2.3. Module current...................................................................................................10
4.2.4. Charging current ................................................................................................10
4.2.5. Load current .......................................................................................................10
4.2.6. Ah – Battery charging meter...............................................................................10
4.2.7. Ah – Battery discharging meter ..........................................................................10
4.2.8. Warning deep discharge protection....................................................................11
4.2.9. Load disconnection.............................................................................................11
5. Function Overview .........................................................................................11
5.1. SOC Calculation .................................................................................................11
5.2. PWM Charge Control .........................................................................................11
5.3. Deep Discharging Protection ..............................................................................12
6. Regulator Settings .........................................................................................12
6.1. Calling up and Modifying the Settings................................................................12
6.2. SOC Setting / Voltage Control.............................................................................12
6.3. Gel / Liquid Battery Type Setting ........................................................................12
6.4. Night Light Function Setting...............................................................................13
6.5. Morning Light Function Setting..........................................................................13
6.6. Default Setting (Presetting) Activation................................................................13
6.7. Auto-test ............................................................................................................14
6.8. Serial Number Query...........................................................................................14
7. Options...........................................................................................................14
7.1. External temperature sensor...............................................................................14
7.2. Alarm contact.....................................................................................................14
8. Error Messages .............................................................................................15
9. Legal Guarantee.............................................................................................17
10. Technical Data ................................................................................................18
Appendix ...................................................................................................................21
External temperature sensor for the PR 2020-IP .............................................................21
Signal contact ................................................................................................................22

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1. Safety instructions and liability disclaimer
1.1. The safety instructions are marked as follows
In this manual, safety instructions for personal protection are marked with this
symbol.
The relevant operational safety notes of the system and regulator are marked
in bold.
1.2. General Safety Instructions
Observe the following while installing the regulator and handling the battery:
Danger of explosion due to improper handling of batteries! Corrosive hazard by
leaking battery acid!
Keep children away from batteries and acid! Smoking, fire and naked lights are
prohibited when handling batteries. Prevent sparking and wear eye protection
gear during installation. Observe and follow the handling instructions in the
user manual and on the battery.
Solar modules generate power from light incidence. Even by low light incidence
solar modules carry the full voltage. Therefore, work cautiously and avoid spark-
ing during all work. Observe the corresponding safety precautions.
During installation and electrical installation, the photovoltaic system’s DC
circuit may carry twice its system voltage value (in the 12 V system up to 24 V,
24 V system up to 48 V).
Use only well-isolated tools!
Do not use any technical measuring equipment that you know is damaged or
defective!
When installing the power line ensure that no fire safety measures are dam-
aged. The regulator may not be installed and operated in moist rooms (e.g. rest
rooms), or rooms, in which easily flammable gasoline mixtures may be present,
such as by gas bottles, paint, lacquer, solvents etc. Do not store any of the men-
tioned mixtures in the room, in which the solar regulator is installed!
If the regulator is operated in a manner not specified by the manufacturer, the
regulator’s constructive protective measures can deteriorate.
The factory signs and marking may not be modified, removed or made unrecog-
nizable. All work must be performed in conformity with the national electrical
specifications and related local regulations!
When installing the regulator in foreign countries, information concerning regu-
lations and protective measures must be obtained from the relevant institutions
/ authorities.
Do not begin the installation until you are sure that you have technically understood
the manual and perform the work only in the order provided in this manual!
The manual must be available during all work performed on the system, third
parties included.

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This manual is a component of the system regulator and must be included with
the regulator when given to a third person.
The Controller is equipped with a low power surge protection. The installer had
to care for a efficient lightning protection.
1.3. Scope of Application
This manual describes the function and installation of a regulator for photovoltaic (PV)
systems for charging 12 V or 24 V lead batteries for recreational, residential, business,
commercial areas and small businesses and telecommunication.
The charge regulator is only suitable for regulating photovoltaic solar modules. Never
connect another charging source to the charge regulator. This can destroy the regulator
and / or source. Consult your specialized dealer or installer if other charging sources
should be used and observe the ”5.1. SOC Calculation” item in this manual.
The regulator is only suitable for the following chargeable 12 V or 24 V battery types:
- Lead storage batteries with liquid electrolytes
- Sealed lead storage batteries; AGM, GEL
The respective battery type must be set on the regulator, see ”6.3. Battery Type Gel / Li”.
Observe the manufacturer’s instructions before connecting the battery.
Important! The regulator is not suited for nickel cadmium, nickel metal
hydride, lithium ions or other rechargeable or non-rechargeable batteries.
Such batteries may not be connected to the regulator. Observe the respec-
tive battery’s safety instructions.
The corresponding manufacture’s installation manual must be observed when
installing the remaining components, e.g. solar module, battery or consumer.
The regulator may only be used for the particular solar applications pro-
vided. Also, observe that the permitted, model-specific, nominal currents
and voltages are not exceeded. No liability shall be assumed for any non-
compliant usage. Carefully handle the product.

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1.4. Liability Disclaimer
The manufacturer cannot monitor the compliance to this manual as well as the condi-
tions and methods during the installation, operation, usage and maintenance of the
system regulator. Improper installation can cause damages and endanger people.
Therefore, we assume no responsibility and liability for losses, damages or costs that
result due to incorrect installation, improper operation, usage and maintenance or in any
manner associated therewith.
Similarly, we assume no responsibility for patent right or other right infringements of
third parties caused by usage of this system regulator.
The manufacturer reserves the right, without prior notification, to make modifications
concerning the product, technical data or installation and operating manual.
Caution:
Opening the regulator, manipulation and repair attempts as well as improper
operation voids the guarantee.

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2. Installation
2.1. Installation Site
Only install the regulator near the battery on a suitable surface. This surface should be
solid, stabile, even, dry and nonflammable. The battery cable should be as short as pos-
sible and have a suitable cable diameter size to minimize loss, e.g. 4 mm² at 20 A and 2
m length.
If the solar battery will be operated under a large temperature range (winter/summer)
the external temperature sensor should be used. A temperature compensated final
charge voltage will extend the batteries lifetime and uses the optimum charge capacity
(see appendix).
Do not install the controller to direct sunlight.
To ensure the air confection on each side keep a distance of 10 cm to the regulator. The
temperature at the installation site may never fall below or exceed the maximal permit-
ted ambient temperature.
10 cm
10 cm
10 cm10 cm
10 cm
10 cm
The integrated LC display should be protected against UV rays (e.g. sunlight). Chronic
exposure to UV rays can permanently discolor the LCD.

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2.2. Connecting the Regulator
Connect the individual components to the symbols provided.
Observe the following connection sequence during commissioning:
1. Connect the battery to the charge regulator - plus and minus
2. Connect the photovoltaic module to the charge regulator - plus and minus
3. Connect the consumer to the charge regulator - plus and minus
The reverse order applies when deinstalling!
Please observe that the automatic adjustment to 12 V / 24 V systems does not
function properly, if this sequence order is not followed. An improper sequence
order can damage the battery!
2.3. Grounding
Grounding the regulator is not technically required when installing a stand-alone solar
system.
Observe, however, the corresponding applicable national regulations. Common ground
connection is possible for all positive connections; however, only a single connection is
possible for a negative ground.
Observe that there is no common connection, e.g. across a ground connection, the
minus module connections, battery minus and load minus. Non-observance can damage
the regulator!
147
55
122
X
147
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122
X

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3. Protective functions of the controller
The regulator is equipped with various devices to protect its electronics, battery and
load. If the regulator’s maximal permitted data are exceeded, the regulator can break
down despite the protective functions. Never improperly connect more than one com-
ponent to the regulator! Error messages (Point 7. Error messages) display any protective
devices triggered. The protective function is automatically reset after remedying the
error.
• Protection against reverse polarity of solar modules
The solar module’s power may not exceed the regulator’s nominal power!
• Protection against reverse polarity of the connected
consumer at the load output
Protects the regulator, not the consumer.
• Protection against reverse polarity of connected battery
Charging and discharging the battery is prevented.
• Short-circuiting at the module input
• Short-circuiting at the load output
• Protection against over charging
Regulator disconnects the connection to the battery and turns off the consumer.
• Open circuit-proof during operation without battery or consumer
Load output is protected from high module open circuit voltage directly flowing to
load side.
• Reverse current protection at night
Prevents reverse current in the solar module at night.
An additional reverse current diode is not necessary!
• Overvoltage and undervoltage protection
Immediately turns off the load output during insufficient or excessive battery voltage.
• Excess temperature protection
If the temperature inside the regulator is too high, the regulator’s load output is
turned off to reduce power loss.
• Overload protection at load output
If the permitted load current is exceeded, the load output is turned off.
• Low power surge protection
A TVS-Diode at the module input protects against overvoltage >47,8 V. The compo-
nent limits the diverted energy to 5 kWpeak.
• Deep discharging protection / low voltage disconnect
Prevents excessive deep discharging or overloading the battery.
• Meets the European CE standards
Note: Failures not protected by the regulator could disable essential functions
and effect the over charge and deep discharge protection. As consequence
uncontrolled gassing or sulphation could damage the battery.

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4. Operating the system regulator
The display shows a variety of system data by symbols and digits. Both buttons control
all settings and display windows.
4.1. Display and Operation Elements
4.2. Display Window
The display modes change automatically. The changing can be stopped and released
with the left key. The bar display shows the actual battery level (SOC = state of charge)
of the battery in each window. If the regulator is set to voltage control, the SOC bar dis-
play does not appear and the battery voltage value replaces the SOC percentage value!
Please observe that the accuracy of the regulator’s display is not comparable to
that of a measuring device!
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55
122
Display window for system
information and messages
Button for switching display
windows or calling up the
settings
Manual load switch, or con-
firmation button in program
mode


SOC hkA
%V
Symbols for current direction
Battery symbol
Symbol for load
Face symbol for
system status
Units display
Sun: Charging/day
Moon: Night
Tools for error
messages
SOC Bar display
7-segment display for
text and numbers

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4.2.1. SOC Window
Displays the charge level, day / night level and consumer
on / off. Instead of the SOC value, the battery voltage is
displayed during voltage control.
4.2.2. Voltage window
Displays the battery voltage measured by the regulator.
4.2.3. Module current
Displays the actual produced solar module‘s current
output.
4.2.4. Charging current
Displays the charging current flowing into battery from
the solar module.
4.2.5. Load current
Displays the current drawn by the load output.
4.2.6. Ah – Battery charging meter
Displays the accumulative sum of recharged Ah since
the initial installation or reset. Press both buttons for 3
seconds to reset the meter to 0. Ever when the battery
is disconnected the value remains. When 99.9 KAh are
reached, it will switch back to 0 Ah.
4.2.7. Ah – Battery discharging meter
Displays the accumulative sum of Ah drawn by load since
the initial installation or reset. Press both buttons for
3 seconds to reset the meter to 0. When 99.9 KAh are
reached, it will switch back to 0 Ah.

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4.2.8. Warning deep discharge protection
As an early warning, the SOC bar or the voltage value
flashes. The face still looks friendly!
4.2.9. Load disconnection
If the deep discharging protection has been activated the
SOC bar or the voltage value flashes. The face looks sad
until the reconnection setpoint is reached.
5. Function Overview
This charging regulator has basic functions for specifying the state of charge (SOC),
charging specification and deep discharge protection that are described in the following
section. Additional functions that can be activated such as the settings, night light func-
tion, auto-test, presetting and serial number query are explained under the correspond-
ing menu items in chapter 6.
5.1. SOC Calculation
During operation, the regulator monitors various parameters (U; I) of the battery and
from that calculates the battery’s charge level (SOC = state of charge). The state of
charge is the energy level still available in the battery. Modifications in the system, e.g.
the battery’s aging process are automatically taken into consideration by the system’s
continuous learning process.
Using this SOC information, you always have an accurate overview on the actual battery
level. Using the SOC, the regulator also controls the selection of the charging procedure
and the deep discharging protection in order to ideally maintain the battery. If one of
the parameters cannot be recorded because for example, a consumer or charging source
is directly connected to the battery, the SOC calculation is invalid. The regulator can then
be set to the more simplified voltage-guided control, see chapter 6.2.
The SOC calculation is restarted each time the regulator is reinstalled.
5.2. PWM Charge Control
The regulator applies a constant voltage charging to the battery. The entire available
electricity provided by the charging source is used for charging the battery until the final
voltage is reached. A pulse width modulator (PWM) regulates the charging current by
briefly closing the module input (shunt charge controller) in the charge control area.
Depending on the actual battery level, various charging procedures, float charging,
boost charging and equalization charging are automatically performed. In doing so, the
settings for the battery and control type are factored in. The final charging voltage is
temperature compensated. Every 30 days a test is automatically performed to determine
if an equalization charging must be carried out.

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5.3. Deep Discharging Protection
The regulator protects the connected battery against an excessive discharging. If the bat-
tery falls below a specified charge level (during SOC control) or battery voltage (during
the voltage-controlled function), the load output is disconnected and the discharge of
the battery is prevented. The display shows the early warning and disconnection during
deep discharging. The setpoints of the deep discharging protection are predefined and
cannot be reset.
6. Regulator Settings
The battery type, control type and night light function can be set in the regulator. Points
for the auto-test and the serial number query are also located within the menu. The set-
tings remain when the battery is disconnected.
6.1. Calling up and Modifying the Settings
Press the left button for at least 3 seconds to open the first setting window (control
type). Press the left button again to call up the various windows.
Press the right button to modify settings. The display begins to flash. Now, with the left
button select the settings options. The setting must be saved with the right button. The
display then stops flashing.
The normal window reappears after a 30 second waiting period or pressing the left but-
ton for 3 seconds. This applies to all windows.
6.2. SOC Setting / Voltage Control
The SOC control is the factory setting. This way, the charging procedure and the deep
discharging protection are controlled by the calculated SOC value for ideal battery
usage. If external loads are connected directly to the battery you can change to voltage
control. The bar
gauge can then be
enabled or disabled.
See chapter 10 for
voltage thresholds.
6.3. Gel / Liquid Battery Type Setting
The standard setting is “Li”. The setting
of the battery type influences the cutoff
voltage of the controller. If you use a Gel
or AGM battery, you have to change the
battery type to GEL.
Caution! An incorrect battery type setting can damage the battery!

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6.4. Night Light Function Setting
This setting provides three options in the following order:
• OFF: The function is deactivated (default).
• Operating time-choice of 1 to 8 hours.
• ON: The consumer output remains on for the entire night.
This function controls the load output only when it is dark (at night). During daylight the
consumer output remains off. The connected solar module records information on the
light intensity.
The load is activated once the solar module detects that it is dark.
Once it becomes light, the regulator deactivates the consumer output regardless which
illumination duration has been selected. Due to different properties of various modules,
the twilight threshold cannot be specified accurately. An activation delay cannot be set
when twilight sets in.
6.5. Morning Light Function Setting
Analog to night light this function can switch on the load in the morning prior to sun
rise. The morning light menu is indicated by the sun symbol instead of the moon.
• OFF: no morning light (factory default)
• 1..12 h: morning light duration prior to sun rise
The load output will be activated the programmed hours before sun rise. “Sunrise” is
assumed 24 h after the last sun rise detection.
Example: morning light programmed to 3 h, last sunrise was at 6:30 h. Then the light
will go on at 3:30 h the next day and go off at daylight.
6.6. Default Setting (Presetting) Activation
Calling up the default settings (PRE) deletes the previous
settings and resets the charge controller to the factory
settings.
The default setting is: SOC Control / Gel Storage Battery / Night
Light OFF

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6.7. Auto-test
The auto-test can determine whether the charge controller is
fully operational.
A) Disconnect solar module and load from the regulator, con-
nect only the battery.
B) Press the right button. The display begins to flash.
C) Start the auto-test with the left button.
D) If there is no error, this window is displayed shortly (1 sec.).
Afterwards, all LCD segments fade in and out for 1 second.
Then the auto-test window reappears in the display.
E) If there is a defect or the module and load is still connected
you will see an error code:
1. digit = “1” : module input defected
2. digit = “1” : load output defected
3. digit = “1” : battery fuse defected
F) In the flashing auto-test window, press the left button
again to repeat the test or the right button to end the test.
6.8. Serial Number Query
Each regulator has a serial number that can be queried using
this window. Press the right button and the SN display begins
to flash. Now, press the left button to display the number. The
digits are displayed successively: - - - 1 2 3 4 5 6 7 8 - - - .
Press the right button to stop or continue the display.
Note the order of the digits for the complete serial number.
7. Options
7.1. External temperature sensor
If the solar battery will be operated under a large temperature range (winter/summer)
the optional external temperature sensor should be used. A temperature compensated
final charge voltage will extend the batteries lifetime and uses the optimum charge
capacity (see appendix).
7.2. Alarm contact
For remote monitoring of an alarm condition the PR2020-IP is available with an alarm
contact. The contact closes, if the SOC of the battery falls below 40 % or if a system
error occurs.
Notes: The external sensor can be installed by the end user, the alarming option
has to be mounted in the factory.

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8. Error Messages
Caution! Please do not open the regulator or attempt to replace
components when troubleshooting. Improper maintenance can be
hazardous to the user and the system.
If the regulator detects errors or unauthorized operating states, it flashes error codes
on the display. Error codes can generally be differentiated, whether there is a temporary
malfunction, e.g. regulator overload or a more serious system error that can be remedied
by appropriate external measures.
Since not all errors can be simultaneously displayed, the error with the highest error
number (priority) is displayed. If several errors are present, the second error code is
displayed after remedying the more significant error.
The following meaning is assigned to the different error codes:
Display Meaning Cause / Remedy
Communication er-
ror with the internal
memory (EEPROM).
Disconnect consumer, solar module
and battery. Reinstall the device. If the
error reoccurs, please contact your
specialized dealer.
Communication error on
the external bus (6-pole
edge connector).
Check the 6-pole plug-in connection
on the edge connector, power supply
and function of the external extension.
If the error reoccurs, please contact
your specialized dealer.
Short-circuit at the exter-
nal temperature sensor.
Check the contact of the 2-pole edge
connector, remove short-circuit. Check
sensor.
Excessive temperature
regulator turned off the
consumer due to internal
over heating.
Let regulator cool. Check the cause for
overheating (installation site, other
heat sources). Possible reduce charge
or load current. Ensure the regulator
has proper ventilation.
Battery voltage too low.
Voltage <10.5 V or
<21.0 V
Check installation. Check battery volt-
age, possibly recharge battery manu-
ally. Consumer connected directly to
the battery can deep-discharge the
battery.
Battery voltage too high.
Voltage >15.5 V or
>31 V.
Check installation. Check battery volt-
age, possibly check additional charge
sources.

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Display Meaning Cause / Remedy
Load current too high.
The regulator’s permit-
ted consumer current
has been exceeded, the
load output has there-
fore been disconnected.
Reduce the load current using the
consumer output.
Perhaps current spikes are occurring
through the consumer.
Try reconnecting the load.
Module current too
high.
The regulator’s permit-
ted input current has
been exceeded.
Reduce the load current or module
power.
Short-circuiting at the
load output.
Remove short-circuit, disconnect
consumer and try to reconnect.
• no module con-
nected or
• short circuit in the
module (moon sym-
bol appears during
the day).
Check module connections.
No battery connected or
connection interrupted.
Supply only by solar module. Connect
battery to regulator and check battery
fuse.
Storage battery con-
nected with reverse
polarity.
Disconnect battery and connect to
regulator with correct polarity.

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9. Legal Guarantee
In accordance with German statutory regulations, there is a 2-year legal guarantee 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. Legal guarantee does not
apply if the fault can be attributed to third parties, unprofessional installation or com-
missioning, 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. Legal guarantee claims are to
be directed to the seller.
The seller must be informed before legal guarantee claims are processed. For processing
a legal 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 replacement. If the
product can neither be repaired nor replaced, or if this does not occur 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 particu-
lar claims for damages due to lost profit, loss-of-use or indirect damages are excluded,
unless liability is obligatory by German law.

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10. Technical Data
The technical data is subject to alterations by the manufacture.
Electrical Data
Operating voltage 12 V or 24 V;
automatic recognition
Voltage range 12 V 6.9 V – 17.2 V
Voltage range 24 V 17.3 V – 43.0 V
Permitted operating
temperature range
–10 °C to +50 °C
Permitted storage
temperature range
–20 °C to +80 °C
Power consumption mA 12,5 mA @ 12 V; 15,8 mA @ 24 V
PWM-Frequency 30 Hz
Maximum input voltage 45 V
Minimum battery voltage 6.9 V
Currents
Max. continuous module current at 25 °C 20 A
Max. continuous load current at 25 °C 20 A
Excess Temperature Protection
Disconnect load >85 °C
Reconnect load <75 °C
Data for final charging voltage
Depends on set
battery type
Gel – storage
battery (GEL)
Liquid electrolyte (Li)
Float charge 13.9 V / 28.2 V 13.9 V / 27.8 V
Boost charge; for 2:00 h 14.4 V / 28.8 V 14.4 V / 28.8 V
Equalization charging; for 2:00 h --- 14.7 V / 29.4 V

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30 day maintenance charge, if neces-
sary
14.4 V (28.8 V)
(for 2:00 h)
14.7 V (28.8 V)
(for 2:00 h)
Temperature
compensation
–4 mV per °K and cells (internal sensor
present, optional external sensor possible)
Charge controller activation
Activation threshold of the charge type SOC Control Voltage control
Float charge SOC >=70 % >= 12.7 V resp.
>= 25.4 V
Boost charge SOC
40 % – 69 %
11.7 V – 12.4 V; resp.
23.4 V – 24.8 V
Equalization charge SOC <40 % < 11.7 V resp. 23.4 V
30 day maintenance charge if within 30 days no equalization or boost
charge was active.
Load disconnection
SOC Control Voltage control
Early warning load
disconnection
SOC < 40 % < 11.7 V / 23.4 V
Load disconnection SOC < 30 % < 11.1 V / 22.2 V
Load reconnection SOC > 50 % > 12.6 V / 25.2 V
Bar gauge voltage thresholds
≥13,00V 10 bars
12,90 – 12,99 V 9 bars
12,80 – 12,89 V 8 bars
12,70 – 12,79 V 7 bars
12,50 – 12,69 V 6 bars
12,00 – 12,49 V 5 bars
11,70 – 11,99 V 4 bars
11,10 – 11,69 V 3 bars
11,00 – 11,09 V 2 bars
< 11,0 V 1 bars

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Mechanical Data
Protection type IP 65
Installation wall installation
Weight 350 g
Housing recyclable, plastic housing
Dimensions L x B x H 187 x 44 x 96 mm
Fastening hole clearance vertical 60 mm; horizontal 177 mm
Terminals 10 mm² / AWG: 6
Strain relief 3 x M25 x 1,5 mm
Diameter of cable 9 – 17 mm