Steca Tarom 4545 User manual

Solar Charge Controller
Adjustable, for hybrid and telecommunication systems
Tarom 4545 (12 V/24 V accumulator)
Tarom 4545-48 (12 V/24 V/48 V accumulator)
Installation and operating instructions
GB
Z03 | 17.05

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1 General safety instructions ................................................................................................. 5
2 Identification ...................................................................................................................... 6
3 Scope of delivery ................................................................................................................ 7
4 Proper usage....................................................................................................................... 8
5 Markings ............................................................................................................................ 9
5.1 Symbols for warnings and notices........................................................................... 9
5.2 Keywords................................................................................................................. 9
6 Quick guide ...................................................................................................................... 10
7 Overview of the controller ................................................................................................ 11
8 Menu structure................................................................................................................. 12
9 Installation........................................................................................................................ 13
9.1 Safety instructions................................................................................................. 14
9.2 Connections and operating buttons ...................................................................... 16
9.2.1 StecaLink slave connection ..................................................................... 16
9.2.2 StecaLink master connection .................................................................. 19
9.2.3 Slot for microSD card (in Fig. 1) .......................................................... 20
9.2.4 Relay outputs AUX 1, AUX 2 (, in Fig. 1)........................................... 20
9.2.5 Temperature sensor connection TEMP (in Fig. 1)................................. 21
9.2.6 Open UART interface, 3.3 V (in Fig. 1)................................................. 21
9.2.7 Function ground (in Fig. 1) ................................................................ 22
9.2.8 Operating buttons .................................................................................. 23
9.3 Removing/installing the cover................................................................................ 23
9.3.1 Removing the cover ................................................................................ 23
9.3.2 Installing the cover ................................................................................. 24
9.4 Installing the device............................................................................................... 24
9.5 Establishing the electrical connections .................................................................. 25
9.5.1 Preparing the cables ............................................................................... 26
9.5.2 Connecting the battery........................................................................... 26
9.5.3 Connecting the solar module.................................................................. 27
9.5.4 Connecting loads.................................................................................... 28
9.5.5 Connecting optional components........................................................... 29
Table of contents

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10 Performing initial commissioning ..................................................................................... 31
11 Dismounting the controller .............................................................................................. 34
12 System functions .............................................................................................................. 35
12.1 Protection functions .............................................................................................. 35
12.1.1 Controller overload................................................................................. 35
12.1.2 Overheating of the controller ................................................................. 35
12.1.3 Deep discharging of the battery ............................................................. 35
12.2 Control mode ........................................................................................................ 36
12.3 Battery charging functions .................................................................................... 37
12.3.1 Float charging......................................................................................... 37
12.3.2 Boost charging ....................................................................................... 37
12.3.3 Equalise charging ................................................................................... 38
12.4 Data logger ........................................................................................................... 38
13 Display (layout, function, operation) ................................................................................ 39
13.1 Overview (menu structure) .................................................................................... 39
13.2 Status display ........................................................................................................ 39
13.3 Display of special states......................................................................................... 41
13.4 General operation.................................................................................................. 42
13.5 Advanced operation .............................................................................................. 42
14 Control functions.............................................................................................................. 44
14.1 Overview ............................................................................................................... 44
14.2 Operation .............................................................................................................. 45
14.3 Functionality.......................................................................................................... 47
14.3.1 Deep discharge protection...................................................................... 48
14.3.2 Morning light function ........................................................................... 48
14.3.3 Evening light function ............................................................................ 49
14.3.4 Night light function ................................................................................ 49
14.3.5 Excess energy control ............................................................................. 50
14.3.6 Generator manager ................................................................................ 50
14.3.7 Alarm...................................................................................................... 51
14.3.8 Timer 1 ... 4 ............................................................................................ 51

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14.3.9 StecaLink bus.......................................................................................... 52
14.3.9.1 StecaLink slave address setting .............................................. 52
14.3.9.2 StecaLink master setting ........................................................ 53
14.3.9.3 Changing the slave settings .................................................. 54
14.3.10 SD card ................................................................................................... 56
15 Troubleshooting................................................................................................................ 58
15.1 Event messages ..................................................................................................... 58
15.2 Errors without event messages.............................................................................. 64
15.3 Self test ................................................................................................................. 65
16 Maintenance..................................................................................................................... 66
16.1 Controller .............................................................................................................. 66
16.1.1 Removing dust........................................................................................ 66
16.1.2 Removing heavy soiling .......................................................................... 66
16.1.3 Checking the charging functionality ....................................................... 67
16.1.4 System.................................................................................................... 67
17 Disposal............................................................................................................................ 68
18 Technical data................................................................................................................... 69
18.1 Controller .............................................................................................................. 69
18.2 Connection cables ................................................................................................. 71
18.3 Protocol of the open UART interface ..................................................................... 72
18.3.1 Settings .................................................................................................. 72
18.3.2 UART Data .............................................................................................. 73
18.4 Recording data on an SD card ............................................................................... 75
18.4.1 Master data file ...................................................................................... 76
18.4.2 TIMECHG data file................................................................................... 77
18.4.3 PA HS400 data file .................................................................................. 78
19 Guarantee conditions ....................................................................................................... 79
19.1 Exclusion of liability............................................................................................... 79
20 Contact............................................................................................................................. 80
21 Notes................................................................................................................................ 81

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1 General safety instructions
QThis document is part of the product.
QOnly technical professionals may perform the work described in this manual.
QInstall and use the device only after reading and understanding this document.
QAlways perform the measures described in this document in the sequence specified.
QKeep this document in a safe place for the entire service life of the device. Pass the document
on to subsequent owners and operators of the device.
QIncorrect operation can reduce solar system yields or damage system components.
QThe device must not be connected to the DC cables if it has a damaged casing.
QIf one of the following components is damaged immediately take the device out of operation
and disconnect it from the battery and modules
– Device (not functioning, visible damage, smoke, penetration of liquid etc.),
– Connected cables,
– Solar module.
Do not switch the system on again before
– the device has been repaired by a dealer or the manufacturer,
– damaged cables or solar modules have been repaired by a technical specialist.
QBattery acid splashes on skin or clothing should be immediately treated with soap suds and
rinsed with plenty of water. Immediately seek medical advice in the case of injuries.
QIf battery acid splashes into the eyes, immediately rinse with plenty of water and seek medical
advice.
QNever cover the device.
QDo not open the casing: Risk of death. Invalidation of the guarantee.
QFactory labels and markings must never be altered, removed or rendered unreadable.
QObserve the manufacturer's manual when connecting an external device that is not described in
this document. Incorrectly connected devices can damage the controller.
QThis device is not intended for
– children,
– persons with physical, sensory or mental impairment,
– persons without sufficient experience or knowledge unless they are instructed in the use of
the device, and initially supervised, by a person responsible for their safety.

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2 Identification
General information
Feature Description
Type Tarom 4545, Tarom 4545–48
Issue version of the manual Z03
Manufacturer's address See nameplate on the charge controller
Optional accessories QExternal temperature sensor Steca PA TS-S
QCurrent sensor PA HS400
QStecaLink termination plug
Display
The controller indicates the version of the manual matching the software under ‘Main menu’ 
‘Information’ ‘System info’

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3 Scope of delivery
QTarom 4545 or Tarom 4545–48
QOperating instructions

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4 Proper usage
The solar charge controller, hereinafter named as the controller or device, may only be used in stand-
alone photovoltaic systems for charging and controlling a lead-acid battery containing liquid or gel
electrolyte. The following applies in addition:
QThe controller must not be connected to the public power grid.
QOnly solar modules may be connected to the solar module connection.
QDepending on the battery used, the connected loads must be suitable for use with one of the
following voltages:
Tarom 4545: 12 VDC, 24 VDC
Tarom 4545–48: 12 VDC, 24 VDC, 48 VDC
QThe controller performs the following tasks:
– Monitoring of the battery charging process
– Controlling of the charging process, protection of the battery from overcharging
– Switching loads on and off, protection of the battery from deep discharge

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5 Markings
5.1 Symbols for warnings and notices
Symbol Description Location
General danger warning Manual
Danger from electricity Manual
Read the manual before using the product. Device
Danger from hot surfaces Manual, Device
General information. Manual
The following information describes prerequisites for
further operation
Manual
5.2 Keywords
The following symbols are used in conjunction with the symbols from chapter 5.1.
Keyword Description
Danger immediate danger of death or serious bodily injury
Warning possible danger of death or serious bodily injury
Caution possible danger of light or medium bodily injury
Notice possible damage to property
Note note on operation of the device or use of the manual

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6 Quick guide
DANGER!
Risk of death by electrocution. Observe the safety instructions in chapter 9.1.
Installation
Uninstallation

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7 Overview of the controller
Fig. 1 Overview of casing and connections
1) Technical data at section 18.1.
2) Optional
3) Not included in scope of delivery
Connections
Batteryconnection:terminals1+and1−
Solar module connection: terminals 2+ and
 2−
Load output for connecting the loads:
 terminals3+and3−
Micro SD slot for microSD card
SLAVE IN and SLAVE OUT RJ45 sockets
for StecaLink Bus
MASTER RJ45 socket for StecaLink Bus
Open UART interface, 3.3 V
Temperature sensor connection TEMP for
Steca PA TS-S
AUX 2 relay output
AUX 1 relay output
Other components
External battery fuse (safety fuse or DC line
circuit breaker1) 3)
DC load circuit breake 1) 2) 3)
Left cover
Display
Right cover
ESC, r, s, SET operating buttons
Type plate
Positive ground, optional

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8 Menu structure
For the sake of clarity, only the sand ‘SET’ operating buttons are illustrated.
SET SET SET
SET SET SET
SET SET SET
SET SET SET
SET SET SET SET
SET SET
SET
SET
SET SET
Daily input
Daily load
Information
Load current Clear event log
Event log
Battery type
5)
Time format
Date format
Status display Main menu
Basic setting
Battery voltage
Output settings
Internal data
logger
Charge /
discharge
current
Battery
settings
Battery
capacity
Charge voltage 6)
Contrast
2)
SD card
Date
Time / date
Clear log data
4)
Battery control
mode
Equalisation
cycle Time
Language
Self test
3)SOC
Input current
System
settings
PV current
Operation
mode
Load
AUX 1
AUX 2
Deep discharge
protection
Select function
Function
settings
8)
8)
Evening light
Night light
Morning light
Submenus
Generator
control
Excess energy
control
StecaLink slave
address
SET
SET
SET
SET SET
SET
SET SET
SET
1)
2)
3)
4)
5)
6)
7)
8)
System voltage
Open UART
Temperature
sensor
Device
temperature
Cable
compensation
Available if battery type = lead acid battery. Submenus: On/Off, cycle
Equalisation
charge
duration
Boost charge
duration
Expert menu
Start boost
charge
Battery
temperature
Remaining
capacity
Operating hours
StecaLink
master menu
Add slave
device
Submenus: SOC control mode, sensor member list
7)
Temperature
compensation
Total charge /
discharge current
of battery
Total discharge
current of battery
Total charge
current of battery
Factory reset
Change slave
Delete slave
Timer 1
Timer 4
Submenus for displaying the stored energy, current and voltage, configuration of sensors
Submenus: Datalogger On/Off, load parameter, store parameter
1)
Measurements of registered StecaLink slaves (if available)
Submenus: Float charging, boost charging, equalisation charging (available if battery type = Lead acid battery)
Submenus: On/Off, temperature coefficient
Same menus as Load, additionally with Alarm
Alarm 9)
)
9) Only for AUX 1 and AUX 2

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9 Installation
The following section describes only the installation of the controller. Observe the respective
manufacturer's manual when connecting external components (solar module, battery, load,
sensors).

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9.1 Safety instructions
DANGER!
Risk of death by electrocution! Observe the following safety instructions when performing the
measures described in the installation section.
General information
– Only technical professionals may perform the work described in the 'installation' section.
– Do not open the controller case.
– All covers must be installed during operation.
– Always take the following measures before working on the controller:
1. Switch off all loads.
2. If present, switch off the DC load circuit breaker (solar module) and secure it against
being switched on again or safely cover the solar module (wind).
3. Switch off the external battery fuse: Remove the fuse insert from the fuse holder (safety
fuse) or switch off the DC line circuit breaker and secure it against being switched on
again.
4. Disconnect the battery cable from both battery terminals.
Cable connections
– The module cables carry voltage when the solar module is illuminated.
– Insulate exposed cable ends with insulation tape or wire connector blocks.
– Connect the cables for the battery, solar module and loads to the controller in the
described sequence.
– Secure the connected cables with a strain relief clamp, see Quick Guide section 6. Clearance
of strain-relief to controller: 200 mm.
– Connect only 1 cable to each connection terminal.
– Cables used: Observe the specifications in the Technical data section.
– Lay the cables so that
– connections cannot accidentally come loose,
– persons cannot tread on or trip over these,
– fire protection devices must not be impaired.
– The entire installation must be designed with Protection Class II if the open-circuit module
voltage exceeds 60 V DC at least once anywhere over the entire temperature range.
– Observe all applicable installation regulations and standards, national laws and connection
values specified by the regional power supply company.
Fuses and switching devices
Installation of an external battery fuse (line fuse or DC line circuit breaker) is mandatory.
Observe the following:
– Mount the external battery fuse directly next to the battery.
– The external battery fuse must conform to the specifications in the technical data section.
– The external battery fuse is not included in the scope of delivery.

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WARNING!
Danger of acid injuries.
– Do not subject the battery to open flames or sparks.
– Provide adequate ventilation in the installation location of the battery. Inflammable gases
can escape from the battery.
– Follow the charging instructions of the battery manufacturer.
ATTENTION!
Danger of destroying the device through overloading.
– Conform to the technical specifications, especially the connection values. See the type plate
and section 18.
– When selecting the solar module, note that the open-circuit module voltage is higher than
the value specified on the type plate at temperatures below 25 °C.
– Connect only 1 controller to each solar module.
– Tighten the connection terminals as shown: Battery, solar module and loads with
2.5 ... 4.5 Nm

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9.2 Connections and operating buttons
The following section describes the connections and operating buttons. For information on the dis-
play and operation see section 13.
9.2.1 StecaLink slave connection
1. Set a unique slave address at the device with the StecaLink slave connection; see section
14.3.9.1 ‘StecaLink slave address setting’.
2. Connect the StecaLink slave connection to the ‘StecaLink master’ connection of the superor-
dinate master device.
3. Use a free ‘StecaLink slave’ connection for looping the connection through further slaves.
NOTICE!
– The StecaLink slave connection is an RS-485 communication interface using a proprietary
bus protocol.
– The StecaLink slave connection allows connection of superordinate communication levels
and control devices. The superordinate communication partner functions as the master and
controls the device via the StecaLink slave interface.
– A standard RJ45 network cable (CAT-5 Patch cable, 1:1) is used for connecting StecaLink
communication bus members.
– The last unused StecaLink slave connection of a communication chain must be terminated.
A termination plug can be acquired separately at your Steca dealer.
– A StecaLink slave device may only be connected to one StecaLink master. Multiple Steca-
Link slave devices are connected to form a communication chain. Only one StecaLink slave
device is connected to the StecaLink master device.
– Up to 5 PA HS 400 current sensor units can be connected via the StecaLink master socket
to a Tarom 4545 / Tarom 4545-48.
– The StecaLink slave bus is not galvanically isolated from the power supply unit of the
Tarom 4545 / Tarom 4545-48.
– At the device, at the StecaLink master connection, a supply voltage is available for slave
devices that do not have an own voltage supply. By connecting a slave to the StecaLink
master, the supply voltage is looped through the slave members.
– Each slave must have its own unique address within a range of 1 to 99. No duplicate ad-
dresses may be present. Set the address of the slave according to the slave manual.
– The maximum length of the entire bus cabling should not exceed 25 m.
– The Tarom 4545 / Tarom 4545-48:
– has 2 StecaLink slave bus connections,
– is a slave for Tarom MPPT 6000-M devices at the StecaLink slave connection,
– has a StecaLink master connection,
– is always the master at the StecaLink master connection.

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4. Terminate the free ‘StecaLink slave’ connection of the last slave member using the terminati-
on plug.
Fig. 2 Bus cabling example using an MPPT 6000-M, MPPT 6000-S, one Tarom 4545/4545-48
and PA HS400 current sensors
Fig. 3 Bus cabling example using one Tarom 4545/4545-48 and one or more PA HS400
current sensors
Fig. 4 Example of connecting a PC to the Tarom 4545/4545-48, e.g. for the update function
Fig. 5 The connection of Tarom 4545/4545-48 slave connection to other Tarom 4545/4545-48
slave connections, other charge controllers or PA HS400 without master is not permitted
Fig. 6 The connection of Tarom 4545/4545-48 master connection to other Tarom 4545/4545-48
slave connections is not permitted
Tarom
4545 / 4545-48
StecaLink
Slave Slave
StecaLink
Master
PA HS400
StecaLink
Slave Slave
......
PA HS400
StecaLink
Slave Slave
Term.
Tarom
4545 / 4545-48
StecaLink
Slave Slave
StecaLink
Master
Tarom
4545 / 4545-48
StecaLink
Slave Slave
StecaLink
Master

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The bus cable pin assignments are specified in the following table.
Pin 1234 567 8
Signal
(master
socket)
A B - + Battery voltage1) - - GND 2) GND 2)
Signal
(slave
socket)
A B - - - - GND 2) GND 2)
1) The battery voltage is looped through from the master as supply voltage for slaves.
2) GND or rather battery minus

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9.2.2 StecaLink master connection
1. Set a unique slave address on the device with the StecaLink slave connection, see section
14.3.9.1 'StecaLink slave address setting'.
2. Plug the slave device into the StecaLink master connection. Connect the 'MASTER for Steca-
Link Bus' connection to the 'SLAVE IN for StecaLink Bus' connection.
3. If further slaves shall be connected, connect them via the slave device, at its free 'SLAVE OUT
für StecaLink Bus' connection.
NOTICE!
– The StecaLink master connection is an RS-485 communication interface using a proprietary
bus protocol.
– The StecaLink master connection allows the connection of subordinate communication
partners.
– The StecaLink slave devices connected to the StecaLink master connection are controlled by
the Tarom 4545 / Tarom 4545-48 as communication master.
– E.g. external current sensors PA HS400 can be connected to the StecaLink master connecti-
on.
– A standard RJ45 network cable (CAT-5 Patch cable, 1:1) is used for connecting StecaLink
communication bus members.
– Termination plugs for the StecaLink communication bus are available as accessories.
The communication network connected to the StecaLink master must be terminated at the
last free StecaLink slave connection.
– No further StecaLink master may be used in the communication network that is connected
to the StecaLink master connection.
– The Tarom 4545 / Tarom 4545-48 can manage a maximum of 5 PA HS400 units.
– Each slave must have its own unique address within a range of 1 to 99. No duplicate ad-
dresses may be present. Set the address of the slave according to the slave manual.
– The maximum length of the entire bus cabling should not exceed 25 m.
– The controller:
– has 1 StecaLink master connection,
– has 2 StecaLink slave bus connections,
– is always the master at the StecaLink master connection.
ATTENTION!
Tarom 4545 / Tarom 4545-48 devices can only communicate via the StecaLink bus if they have
a serial number from 757324 / 757325 or higher, as well as a APP software version 1.7.0 or
higher.
It is never permitted to integrate more than one Tarom 4545 / Tarom 4545-48 in a StecaLink bus
because otherwise dangerous compensation currents may occur!

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4. On the last slave member, terminate the free 'StecaLink Slave' connection with the terminati-
on plug.
5. Register and configure the added StecaLink slave devices on the master device, see section
14.3.9.2 ' StecaLink master setting'.
Fig. 7 Master/slave connection of two Tarom 4545/4545-48 via the master connection
is not possible
Fig. 8 Tarom 4545/4545-48 / Tarom MPPT 6000-S connection is not possible without Tarom
MPPT 6000-M
StecaLink bus cable pin assignment: see page 23.
9.2.3 Slot for microSD card (in Fig. 1)
Data can be logged and parameters can be saved on an inserted microSD card (not included in
scope of delivery). See 'Commissioning of the microSD card' in section 9.5.5.
9.2.4 Relay outputs AUX 1, AUX 2 (, in Fig. 1)
The relay outputs can be used for switching devices or loads (loads via an external power relay).
Devices connected to the relay outputs are controlled via the control functions provided by the con-
troller. Relay output pin assignments:
AUX 1 AUX 2 Description
1 (NC) 4 (NC) Normally closed relay contact; the contact is closed when the relay is
switched off.
2 (COM) 5 (COM) Common relay contact
3 (NO) 6 (NO) Normally open relay contact; the contact is open when the relay is
switched off.