Votronic VBCS 30/20/250 Triple User manual

Mounting Instructions and Operating Manual for Unit Combination of
Mains Charger, Charging Converter and MPP Solar Controller including Battery Trainer
VBCS 30/20/250 Triple Converter VCC 12 V-12 V/30 A, AC Mains 12 V/20 A, MPP Solar 250 Wp No. 3241
VBCS 45/30/350 Triple Converter VCC 12 V-12 V/45 A, AC Mains 12 V/30 A, MPP Solar 350 Wp No. 3243
VBCS 60/40/430 Triple Converter VCC 12 V-12 V/60 A, AC Mains 12 V/40 A, MPP Solar 430 Wp No. 3245
All-automatic battery charger with 3 charging sources for optimum battery charging during
mains operation and solar operation, designed for motor homes and intervention vehicles.
Please completely read this operating and installation manual thoroughly prior to connection and
start-up, in particular "Safety Regulations and Appropriate Application", s. page 18.
VOTRONIC chargers of series "VBCS Triple" excel by their compact design, low weight (high-frequency switching power
supply, Switch Mode Technology), as well as the intelligent microprocessor charging control with characteristic lines of
charging „IU1oU2oU3“ and dynamic charging time calculation.
8 charging programs stored in the memory for Lead-Acid, Gel and AGM, as well as advanced Lithium LiFePO4 Batteries,
ensure unattended, quick and careful full charging from any charging state with subsequent trickle charging and maintenance
of the battery and simultaneous supply of the connected consumers 12 V during the entire charging process. Consumed
energy will be compensated immediately.
Mains Operation, during standstill operation at the external socket of the mains supply:
The full charging capacity in the universal wide range from 110 V AC - 230 V AC without any switching is available
worldwide, even in case of large deviations in the power supply (low voltage/overvoltage, sine curve, frequency).
Efficient charging of the board battery and supply of the 12 V consumers via mains.
Auxiliary charging 12 V/4-5 A for support charging and trickle charging of the vehicle's (lead) starter battery in case of
extended standstill periods.
Due to the long-term characteristic lines of charging, the unit may be connected continuously to the mains (such as for
standstill periods or winter breaks).
Charging Converter, "B2B" Operation, mobile operation from dynamo and starter battery (Battery to Battery):
The efficient charging converter (booster) allows full charging of the board battery during driving.
It increases/reduces the voltage to the level, which is required for precise charging of the board battery with the
optimum characteristic line of charging.
Cable losses and considerable voltage fluctuations of the dynamo, known from Euro 6 vehicles, are completely
compensated.
The simultaneously supplied 12 V consumers are protected against overvoltage and voltage fluctuations.
Solar Operation, "MPP" (Maximum-Power-Point):
Controllers according to the MPP technology are continuously and automatically calculating the maximum power yield
(MPP) of the solar modules several times per second. This surplus of charging current of 10 % to 30 % ensures short
charging times and the best possible power yield of the solar system.
Auxiliary charging for support charging and trickle charging of the vehicle's starter battery in case of extended standstill
periods.
Terminal "AES", for automatic commutation of refrigerators with "AES" (Automatic Energy Selector, Electrolux /
Dometic) from gas operation to 12 V operation in case of excess solar power.
Pulser Operation, training for the board battery during the charging breaks, if a charging source is not existing:
The battery training protects the unused (lead) battery during the winter break, seasonal operation or extended standstill
periods from premature ageing and failure due to sulphation.
Further Characteristics of the Unit:
The charging voltage being free from peaks is controlled in such a way, that overcharging of the batteries is excluded.
All-automatic Continuous Operation: The charger may be connected continuously to the batteries, thus keeping the full
charge. If the charging source is missing (power failure, engine stop, night), the batteries will not be discharged.
Parallel and Floating Operation: In case of simultaneous consumption, charging of the battery is continued or trickle
charging is effected. Calculation and control of the adaptation of the charging times is effected automatically by the
charger.

--2--
Unattended Charging: Multiple protection against overload, overheating, overvoltage, short- circuit, incorrect
behaviour and back discharge of the battery by electronically controlled gradual reduction down to complete separation
of charger and battery.
Power Pack Function: Allows supply of the consumers without battery (such as during battery replacement).
Integrated On-board Mains Suppression Filter: Unproblematic parallel operation of further charging sources (wind-
driven, motor -driven and petrol-driven generators) at one battery.
Charging Cable Compensation: Automatic compensation of voltage losses on the charging cables.
Connection for Battery Temperature Sensor (included in the standard delivery scope):
Lead batteries (acid, gel, AGM): In case of low outside temperatures, full charging of the weak battery is improved by
automatic adaptation of the charging voltage to the battery temperature, and in case of summery temperatures
unnecessary battery gassing will be avoided.
LiFePO4 Batteries: Battery protection in case of high temperatures or particularly in case of low temperatures < 0°C.
Highly recommended, if the battery temperature might drop below 0 °C during operation.
Lithium LiFePO4 Auto Wake Up: Periodical automatic activation of the battery cell balancing BMS.
Lead Battery regeneration in case of standstill: automatically twice a week to avoid harmful acid accumulation.
Charging aid for totally discharged lead batteries: Gentle preliminary charging of the (lead-acid, gel, AGM) battery to
8 V, followed by powerful support of the battery, in case of possibly switched-on consumers.
Battery Lifetime and Efficiency:
Keep the batteries cool, LiFePO4 preferably above 0 °C. Choose an appropriate location
for installation.
Store only fully charged batteries and recharge them periodically.
Open lead-acid batteries and batteries being "maintenance-free according to EN / DIN":
Check the acid level periodically!
Recharge totally discharged lead batteries immediately!
LiFePO4: Only use complete batteries with BMS and safety circuit.
! Total discharge is absolutely to be avoided !
Observe the "Safety Regulations and Appropriate Application" for the unit,
see page 18!
Installation of the Unit
Install the charger near the board supply battery I (for short charging cables) at a clean, even and hard mounting surface,
which is protected from moisture, humidity and aggressive battery gases. The unit can be installed in any position.
Despite the charger's high efficiency, heat is produced, which is brought out of the casing by means of the built-in fans. The
vent holes at the unit rear should never be covered (minimum distance 10 cm) to ensure full charging capacity. Ensure
sufficient ventilation in the environment of the unit so that the heat can be carried-off.
Otherwise, the unit might effect a slight reduction of the charging capacity in case of increased heating.
Unit Connection
a. Choose the suitable connection plan according to your application. Observe the indications, fuses, polarity
+/-!
b. Produce the power connections observing table 1, page 6 and the
"Recommended Cable Cross-Sections, Cable Lengths and +Fuse Capacities".
Reverse battery (+/-) might result in severe damages of the unit!
c. Produce the control connections. See description from page 7,
"Configuration of the 9-pole Terminal Strip (Sensor Inputs and Terminals)"
Unit Settings
d. Set the battery type "Board I"(design, technology), see 1.) Page 9.
e. Adjust the further settings and functions, set the 8 slide switches, page 12, table 2 and 2.) -- 8.).
Start-up and Function Test:
f. Further description, see page 16.

--3--
Standard Connection Plan incl. Options:
Safety Instruction for all connection methods:
Connection is only allowed to a shock-proof socket, which has been installed according to the valid technical
regulations, protected with max. 16 A (if required, mobile/stationary with a fault current breaker (FI) with a
nominal residual current of 30 mA).

--4--
Connection Plan Special Case "TR"-ByPass Relay
in case of very high consumer current rates,
such as for air-conditioner operation during driving by means of powerful inverter
Instructions for faultless function of this option:
Connect the VAC Triple and the relay with connection cables of a length of approx. 50 cm and with cross-
sections acc. to table 1 (**). The further cabling to the batteries, also with different cross-sections, is to be
effected directly at the relay!

--5--
Connection Plan Special Case for existing Electroblock "EBL", "EVS"etc.:
Use the cabling and the fuses for the electroblock provided by the customer and insert the changeover relay into
the cable to the starter battery (changeover relay only necessary if starter battery should be connected during
motor off (D+ low) with the Output B1). Connect the VBCS Triple with the cross-sections and fuses according to
table 1. If required, combination with special case TR-Bypass Relay, page 4, in the VBCS triple cables.

--6--
Table 1: Recommended Cable Cross-Sections, Cable Lengths and +Fuse Capacities:
Configuration of the 4 large capacity terminals - Com., + Board I, + Start II, + Solar Panels
The central connection point of all minus cables for units and batteries is the –pole of the battery Board I!
If a current measuring shunt is used (for instance, by the battery computer), the central point of the
minus cables is at the measuring shunt.
As indicated, a cable "–Batt." is to be laid separately between the negative poles of the battery
–Start II and –Board I:
In case of insulated bodies!
If required, for relief of the (lightweight) vehicle chassis for the most powerful types VBCS.
Full charging capacity during driving mode is ensured, if the cable cross-sections and cable lengths are
observed, which are indicated in the following tables!
VBCS 30/20/250 Triple
cable
cross
section
cable length
"+ Start II"
cable length
with insulated
construction
"–Batt."
"fuse II"
cable
protection
cable length
"–Com."
to
"–Board I"
cable length
"+ Board I"
"fuse I"
cable
protection
cable lengths
"- and +
solar
panels"
2.5 mm²
-
-
-
-
-
up to 4.5 m
4 mm²
-
-
-
0.5 - 1.5 m
0.5 - 1.5 m
40 A
up to 7 m
6 mm²**
up to 5 m
up to 5 m
50 A
1.0 - 2.5 m
1.0 - 2.5 m
40 A
up to 10 m
10 mm²
up to 8 m
up to 8 m
50 A
2.0 - 4.0 m
2.0 - 4.0 m
40 A
up to 16 m
VBCS 45/30/350 Triple
cable
cross
section
cable length
"+ Start II"
cable length
with insulated
construction
"–Batt."
"fuse II"
cable
protection
cable length
"–Com."
to
"–Board I"
cable length
"+ Board I"
"fuse I"
cable
protection
cable lengths
"- and +
solar
panels"
4 mm²
-
-
-
-
-
up to 4.5 m
6 mm²
-
-
-
0.5 - 1.5 m
0.5 - 1.5 m
60 A
up to 7.5 m
10 mm²**
up to 5 m
up to 5 m
80 A
1.0 - 2.5 m
1.0 - 2.5 m
60 A
up to 12 m
16 mm²
up to 9 m
up to 9 m
80 A
2.0 - 4.0 m
2.0 - 4.0 m
60 A
up to 19 m
25 mm²
up to 14 m
up to 14 m
80 A
3.0 - 6.0 m
3.0 - 6.0 m
60 A
-
VBCS 60/40/430 Triple
cable
cross
section
cable length
"+ Start II"
cable length
with insulated
construction
"–Batt."
"fuse II"
cable
protection
cable length
"–Com."
to
"–Board I"
cable length
"+ Board I"
"fuse I"
cable
protection
cable lengths
"- and +
solar
panels"
4 mm²
-
-
-
-
-
up to 4 m
6 mm²
-
-
-
-
-
up to 6 m
10 mm² **
-
-
-
0.5 - 2.0 m
0.5 - 2.0 m
80 A
up to 10 m
16 mm²
up to 7 m
up to 7 m
100 A
1.5 - 3.0 m
1.5 - 3.0 m
80 A
up to 16 m
25 mm²
up to 10 m
up to 10 m
100 A
2.5 - 5.0 m
2.5 - 5.0 m
80 A
-
** Special Case: "TR" ByPass Relay in case of very high consumer current rates, page 4,
Cross-section to be used for the two connection cables 50 cm between
VBCS Triple and "TR"-ByPass high-capacity cutoff relay 12 V / 200 A, Order No. 2201.

--7--
Connection of the 9-pole Terminal Strip (Sensor Inputs, Terminals):
Plug-in Terminal Strip: In case of limited space, the strip can be withdrawn and inserted at any time for easy cable
connection.
Cable Cross-Sections: 0,75 mm2or more.
Length to be stripped: approx. 6 mm
Protection: All inputs and outputs at this strip are protected against overvoltage, reverse battery and overload.
The rating of all outputs is up to max. 1 A, and they are protected by means of a self-resetting thermal fuse.
"T T": Measuring input for the temperature sensor of the supply battery "Board I"
Connect the sensor (included in the standard delivery scope) to the terminals "T T" (any polarity). Further details concerning
the functions of the sensor can be drawn from the paragraph "Battery Temperature Sensor" and from the characteristic lines
of charging.
"Ss-" and "Ss+": Measuring inputs for accurate battery voltage, cables voltage sensor Sense:
The unit uses the sense cables for the exact measurement and control of the charging voltage at the battery, independently
of the voltage losses on the charging cables. For this, connect the sense cables "SS" and "SS+" directly to the poles of the
battery board I. Never connect them to the interconnected distributors or the like!
If several batteries are connected in parallel as battery system (battery bank), cross connection is required:
Connect "SS-" to the negative pole of the 1st battery,
Connect "SS+" to the positive pole of the 2nd or last battery of the system.
The charger will automatically recognize and evaluate the sensor cables.
If the sensor cable is not installed or in case of a cable break or fuse failures, it will be switched to normal
operation with charging cable compensation, to wit, calculated compensation of the voltage losses on the
charging cables within the values of table 1.
"TR - OK": Terminal for High-current Bypass Relay TR or Pilot Lamp OK (Option):
Connection Plan: „TR“-ByPass Relay in case of very high consumer current rates Further details concerning the functions can
be drawn from the paragraph "Further Settings and Functions Slide Switches", 6.) "TR - OK", page 13.
If not used, the terminal is to be left free.
"+86": Terminal Engine Immobilizer of the Vehicle (Option):
If the engine should be started by mistake while the vehicle is still connected to mains, this unit output and a connected
external relay in the start circuit can be used to prevent the engine start.
This terminal provides a signal 12 V, as long as the VBCS Triple is connected to mains. It can also be used for purposes of
control and display.
If not used, the terminal is to be left free.
"D+": Control input of the dynamo for the charging converter (B2B-Booster) operation ON / OFF:
Connect the terminal „D+“ directly to the existing signal in the vehicle. The D+ signal is preferably to be used for the "active
dynamo".
If the D+ signal does not exist in the vehicle, the signal "Ignition ON" (terminal 15) can be used for unit control.
Attention: When the motor is not running, the starter battery might be discharged!
The use of a "D + simulator" cannot be recommended due to the solar charge of the starter battery, see page 16.
"Sw": Control Input of the BMS of a LiFePO4 Battery for Locking of the Charging (Option):
The connection can be connected to the terminal charging stop/warning/error of a LiFePO4 battery. Thus, the battery is able
to disable or activate further charging at any time.
Depending on the battery type, the input can be switched to a battery signal "active 12 V" (high signal) or "active 0 V" (low
signal), and it is only active, if the characteristic lines LiFePO4 are set.
Further details concerning the function can be drawn from the paragraph
"Further Settings and Functions Slide Switches", 4.) Activate input charging stop "Sw".
If not used or for lead-acid/Gel/AGM batteries, the terminal is to be left free.
"AES": Signal output for refrigerators with Automatic Energy Selector (option):
The delivery scope of Dometic / Electrolux and of other companies includes "AES" refrigerators with all-automatic energy
selection (230 V AC, 12 V DC or gas).
Particularly in summer, a lot of excess energy might be produced due to strong solar radiation, full batteries and low energy
consumption, which is left unused. The solar controller recognizes this condition and uses the "AES" output to give a signal to
the refrigerator, which will switch from gas operation to 12 V operation to benefit from the excess energy (gas saving).

--8--
Connection:
Lead a single-pole cable (0.5-1.5 mm²) from the unit's terminal "AES" to the refrigerator's terminal "T10" or "S+".
For "AES" operation please make sure that the "heating cartridge" of the refrigerator is also supplied with 12V!
Function:
The solar controller recognizes excess power (the lighting LED „Solar“ extinguishes for a short moment every 2 s). Then, the
refrigerator switches from gas operation to 12 V operation. This mode will be kept for at least half an hour to avoid that the
refrigerator will be "swinging" too quickly between 12 V operation and gas operation.
Should the solar power be still sufficient, the 12 V operation of the refrigerator will be kept.
Should the solar power be insufficient, "AES" will be switched-off by the solar controller, the refrigerator will be switched to
gas operation, it will keep this mode for at least half an hour, and the solar power will be used for recharge of the (possibly
slightly discharged) battery. This mode of operation can only be taken into account in case of sufficient efficiency of the solar
panel and under favourable conditions, such as 110 Wp, better from 150 Wp or more.
Optionally:
Optionally, small 12 V consumers can be operated at the AES output, such as 12 V fans, car relays or refrigerators with
control input D+ (Thetford etc.).
For these applications, it must be observed, that the output must be active for at least half an hour.
If not used, the terminal is to be left free.
Battery Temperature Sensor:
Connect the temperature sensor 825 (included in the standard delivery scope) to the terminals „T T“ (any polarity).
The temperature sensor controls the temperature of the supply battery board „I“.
Ensure that the installation place of the sensor is not influenced by any source of heat (engine heat, exhaust, heater etc.)!
Lead-Acid, Gel, AGM Batteries:
Installation: The thermal contact of sensor and battery inside temperature should be well. Thus, it should be screwed down
to the negative pole or positive pole of the battery. It is also possible to fasten it at the sidewall centre of the battery casing.
Function: The temperature-dependent charging voltage of battery I will be adapted automatically to the battery temperature
(automatic temperature compensation). The temperature sensor measures the battery temperature. In case of low
temperatures (winter operation), the charging voltage will be increased, in order to improve and accelerate full charging of
the weak battery. Sensitive consumers are protected by a limitation of the voltage in case of very low outside temperatures.
In case of summery temperatures, the charging voltage is reduced to minimize the load (gassing) of the battery and to extend
the lifetime of gas-tight batteries.
Battery Protection: In case of excessive battery temperatures (from +50 °C), the charging voltage will be reduced strongly to
safety charging voltage, approx. 12.80 V, for battery protection, and the maximum charging current rate will be halved
(safety mode, LED "Board I" is flashing). Any charging data being recorded hitherto will be kept in memory. Battery charging
is then interrupted, but the supply of consumers being possibly connected will be continued by the unit, and the battery is
allowed to cool down. After that, automatic charging will be resumed. Also refer to "Lead Batteries, 4 Characteristic Lines,
Charging Voltage Rates and Temperature Compensation", from page 9.
The unit recognizes automatically a missing sensor, cable break or short-circuit of the sensor cables, as well as unreasonable
measuring values. In that case, it will switch automatically to the usual charging voltage rates of 20 °C / 25 °C being
recommended by the battery manufacturers.
LiFePO4 Batteries:
Installation: The thermal contact of sensor and inside temperature of the battery should be well. Thus, it should be screwed
down to the negative pole of the battery, because in most of the cases, this is the cooler side (the positive pole is often
falsified with the exhaust heat of internal fuses, electronic systems for cell equalization, balancers etc.)!
Function: In case of abnormal battery temperatures, such as < -20 °C, > 50 °C, the charging voltage will be reduced strongly to
safety charging voltage, approx. 12.80 V, for battery protection, and the maximum charging current rate will be halved
(safety mode, LED "Board I" is flashing). Any charging data being recorded hitherto will be kept in memory. Battery charging
is then interrupted, but the supply of consumers being possibly connected will be continued by the charger until the battery
temperature is again in the admissible range. After that, automatic charging will be resumed.
In case of temperatures below 0 °C, the charging current will be reduced considerably for battery protection, the LED
"Board I" will extinguish every 2 seconds, and longer charging times can be expected. Also refer to 4 Characteristic Lines for
"LiFePO4 Batteries, Charging Voltage Rates and Temperature Control", from page 10.
Attention: If the characteristic line had been set for a LiFePO4 battery, the temperature sensor 825 must be
connected for reasons of battery safety. Otherwise, the unit does not operate, and the LED "Main Charging"
will be flashing!

--9--
Unit Settings:
Carefully move the 12 micro slide switches behind the front panel of the unit to the
desired position using a small screw-driver.
The switch actuators are shown in white.
1.) How to Set the battery type "Board I"- (Design, Technology):
8 Charging programs for the different battery types are stored in the unit. They can be
selected by means of the upper 4 slide switches:
If not being specified divergently by the battery manufacturer, the suitable charging program for
the supply battery Board I can be determined by means of the following description and the
technical data (voltage rates U1 and U2).
The possible parallel/floating operation with consumers being connected to the battery
Board I is also automatically considered by all charging programs.
TS = Temperature Sensor (Effect with/without connection of the temperature sensor)
Lead Batteries (Acid, Gel, AGM):
4 Characteristic lines, charging voltage rates and temperature compensation for batteries in lead technology:
1"Lead Acid" Switch Position
U1=14.40 V U2=13.50 V U3=13.20 V
2-6 h 24 h Continuous
Regeneration 2x per week for 1 h
at mains operation
Universal charging program for
Acid batteries according to DIN 57 510/VDE 0510
for charging and trickle charging of
supply (board) batteries.
Ensures short charging times, high charging factor and
acid mixing for open standard batteries and closed,
SLA, low-maintenance, maintenance-free "non-solid
electrolyte", "lead-acid", drive, lighting, solar and heavy duty batteries. Also suitable for recently developed batteries (low-
antimonous, with silver-alloy, calcium or similar) and batteries with low (L) and very low (VL) water consumption.
2"Gel" Switch Position
U1=14.40 V U2=13.80 V U3=13.50 V
6-12 h 48 h Continuous
Regeneration 2x per week for 1 h
at mains operation
Adapted to closed, gas-tight
Gel/dryfit batteries VRLA with
determined electrolyte, which are
generally requiring longer dwell times U1 to achieve
particularly high capacity storage and to avoid total
discharge (becoming deaf) of the battery, such as
EXIDE, Sonnenschein, "dryfit", Varta, Bosch, Banner,
Mobil Technology etc. If not being specified
divergently by the battery manufacturer, also recommended for batteries in round cell technology, such as EXIDE MAXXIMA
(DC).

--10--
3"AGM 1 14.4 V" Switch Position
U1=14.40 V U2=13.50 V U3=13.20 V
1.5-5 h 24 h Continuous
Regeneration 2x per week for 1 h
at mains operation
Adapted to closed, gas-tight
AGM (absorbed glass mat)/lead-
fleece batteries VRLA with an indicated
charging voltage of "14.4 V".
4"AGM 2 14.7 V" Switch Position
U1=14.70 V U2=13.60 V U3=13.20 V
1.5-5 h 24 h Continuous
Regeneration 2x per week for 1 h
at mains operation
Adapted to closed, gas-tight
AGM (absorbed glass mat)/lead-
fleece batteries, Lead Crystal, VRLA with an indicated
charging voltage of "14.7 V or 14.8 V" and also
„Lead Crystal“ Batteries (14,7V).
It is highly recommended to check the specification
sheet of the battery concerning the high
charging voltage U1 14.7 V!
LiFePO4 Batteries:
4 Characteristic lines, charging voltage rates and temperature control adapted to lithium batteries:
The charging regulations of the battery manufacturer are absolutely to be observed!
An operation of the unit at a LiFePO4 battery without BMS Battery Management System
and without equalization charging of the cells (balancing) as well as safety circuit is not
admissible!
The battery temperature sensor must be installed at the battery (screw to the negative pole)
and connected at the unit. It serves as protection for the battery.
No function without temperature sensor, LED "Main Charging" is flashing!
If possible, the battery temperature should be kept above 0 °C.
5"LiFePO4 13.9 V" Switch Position
U1=13.90 V U2=13.90 V U3=13.50 V
0,5-1h 24 h Continuous
Auto Wake Up every 10 days for 0,4h
at mains operation
Adapted to
Dometic "eStore"
of the indicated capacity rates.
Operation of the battery only with own BMS
and prescribed safety circuit!