Samlexpower PRS 3030 Installation and Operating Instructions

PHOTOVOLTAIK - PHOTOVOLTAICS - PHOTOVOLTAIQUE - FOTOVOLTAICA
Installation and
operating instructions
Solar charge controller
10 A / 15 A / 0 A / 30 A
EN
74.86 | Z0 | 10.7
1. About this manual
These operating instructions are part of the product.
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Read these operating instructions carefully before use,
keep them over the entire lifetime of the product,
and pass them on to any future owner or user of this product.
1.1 Applicability
This manual describes the installation, function, operation and maintenance of the solar
charge controller.
Further technical information is provided in a separate technical manual.
1.2 Users
These operating instructions are intended for end customers. A technical expert must
be consulted in cases of uncertainty.
1.3.Description of symbols
Safety instructions are identified as follows:
SIGNAL WORD
Type, source and consequences of the danger!
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Measures for avoiding danger
Instructions relating to the functional safety of the system are in bold type.
2. Safety
2.1 Proper usage
The solar charge controller may only be used in PV systems for charging and controlling
lead-acid batteries in accordance with this operating manual and the charging specifications of the battery manufacturer.
2.2 Improper usage
No energy source other than a solar generator may be connected to the solar charge
controller. No mains devices, diesel generators or wind generators may be connected.
Do not connect any defective or damaged measuring equipment.
2.3 General safety instructions
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Follow the general and national safety and accident prevention regulations.
Never alter or remove the factory plates and identification labels.
Keep children away from PV systems.
Never open the device.
2.4 Other risks
Danger of fire and explosion
Do not use the solar charge controller in dusty environments, in the vicinity of
solvents or where inflammable gases and vapours can occur.
 No open fires, flames or sparks in the vicinity of the batteries.
 Ensure that the room is adequately ventilated.
 Check the charging process regularly.
 Follow the charging instructions of the battery manufacturer.
Battery acid
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Acid splashes on skin or clothing should be immediately treated with soap suds and
rinsed with plenty of water.
If acid splashes into the eyes, immediately rinse with plenty of water. Seek medical
advice.
2.5 Fault behaviour
Operating the solar charge controller is dangerous in the following situations:
•
•
•
•
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The solar charge controller does not appear to function at all.
The solar charge controller or connected cables are visibly damaged.
Emission of smoke or fluid penetration.
When parts are loose.
In these cases immediately remove the solar charge controller from the solar
modules and battery.
3. Description
3.1 Functions
The solar charge controller
• monitors the state of charge of the battery bank,
• controls the charging process,
• controls the connection/disconnection of loads.
This optimises battery use and significantly extends its service life.
A battery charging algorithm protects the battery from harmful states. Activation of
the three deep discharge functions (LVW, LVD and LVR) is dependent upon the state of
charge (SOC). The switching thresholds lie within the corresponding voltage window in
accordance with the discharge or charging current.
3.2 Construction
1
The solar charge controller consists of the
following components:
2
1. info LED
. 4 LEDs for displaying the state of charge
(red, yellow, green 1 and green 2)
3. terminal block for connecting the solar
module
4. terminal block for connecting the battery
3
4
5
5. terminal block for connecting the loads
loads
3.3 LED displays
LED
Status
Meaning
Info LED
illuminates
green
flashes red
Red LED
flashing quickly battery empty, state of charge < 40 %
when the battery continues to be discharged the
deep-discharge deactivation is triggered
flashing
deep-discharge deactivation, state of charge <
30 %
illuminates
battery weak, state of charge < 50 %
Yellow LED
normal operation
a fault exists (see "Faults and remedies")
flashing
1. green LED
2. green LED
switch-on threshold after deep-discharge deactivation has not yet been reached,
state of charge is 40 % to 50 %
illuminates
battery good, state of charge > 50 %
illuminates
battery full, state of charge > 80 %
flashing quickly battery full, charge regulation active,
i.e. charging current reduced
4. Installation
WARNING
Danger of explosion from sparking! Danger of electric shock!
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The solar charge controller may only be connected to the local loads and the battery by trained personnel and in accordance with the applicable regulations.
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Follow the installation and operating instructions for all components of the PV system.
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Ensure that no cables are damaged.
4.1 Mounting the solar charge controller
4.1.1
Mounting location requirements
• Do not mount the solar charge controller outdoors or in wet rooms.
• Do not subject the solar charge controller to direct sunshine or other sources of
heat.
• Protect the solar charge controller from dirt and moisture.
• Mount upright on the wall (concrete) on a non-flammable substrate.
• Maintain a minimum clearance of 10 cm below and around the device to ensure
unhindered air circulation.
• Mount the solar charge controller as close as possible to the batteries (with a safety
clearance of at least 30 cm).
4.1.2 Fastening the solar charge controller
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Mark the position of the solar charge controller fastening holes on the wall.
Drill 4 Ø 6 mm holes and insert dowels.
Fasten the solar charge controller to the wall with the cable openings facing downwards, using 4 oval head screws M4x40 (DIN 7996).
4.2 Connection
4.2.1 Preparing the wiring
The cross section of the connection cable depends on the power output of the
solar charge controller.
Controller type
10 A
15 A
20 A
30 A
Load/module
current
10 A
15 A
20 A
30 A
Cross-section
AWG
Insulation
6 mm2
10 mm2
10 mm2
16 mm2
10
8
8
6
85 °C
85 °C
85 °C
85 °C
The table above applies to the following cable lengths:
• 10 m solar module connection cable
• 2 m battery connection cable
• 5 m load connection cable
Consult a dealer if the specified cable lengths are inadequate.
An additional external fuse (not provided) must be connected to the battery connection cable, close to the battery pole.
The external fuse prevents cable short circuits. A 40 A fuse can be used for all controller
types.
4.2.2 Connection
WARNING
Danger of explosion from sparking! Danger of electric shock!
Solar modules generate electricity under incident light. The full voltage is present, even
when the incident light levels are low.
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Protect the solar modules from incident light during installation, e.g. cover them.
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Never touch uninsulated cable ends.
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Use only insulated tools.
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Ensure that all loads to be connected are switched off. If necessary, remove the
fuse.
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Connections must always be made in the sequence described below.
Connection sequence
1. battery
2. solar module
3. loads
2
1
3
1st step: Connect the battery
 Label the battery connection cables as a plus cable (A+) and a
minus cable (A–).
 Lay the battery cables in parallel between the solar charge controller and the battery.
 Connect the battery connection cable with the correct polarity to the middle pair of
terminals on the solar charge controller (with the battery symbol).
 If necessary, remove any external fuse.
 Connect battery connection cable A+ to the positive pole of the battery.
 Connect battery connection cable A– to the negative pole of the battery.
 Replace the external fuse in the battery connection cable.
 If the connection polarity is correct, the info LED illuminates green.
2nd step: Connect the solar module
 Ensure that the solar module is protected from incident light.
 Ensure that the solar module does not exceed the maximum permissible input current.
 Label the solar module connection cables as a plus cable (M+) and
a minus cable (M–).
 Lay both solar module connection cables in parallel between the solar module and
the solar charge controller.
 First connect the M+ solar module connection cable to the correct pole of the left
pair of terminals on the solar charge controller (with the solar module symbol),
then connect the M– cable.
 Remove the covering from the solar module.
3rd step: Connect loads
Notes
• Connect loads that must not be deactivated by the solar charge
controller deep discharge protection, e.g. emergency lights or radio
connection, directly to the battery.
• Loads with a higher current consumption than the device output
can be directly connected to the battery. However, the solar charge
controller deep discharge protection will no longer intervene. Loads
connected in this manner must also be separately fused.
 Label the load connection cables as a plus cable (L+) and a minus cable (L–).
 Lay the load connection cables in parallel between the solar charge controller and
the load
 First connect the L+ load cable to the correct pole of the right pair of terminals on
the solar charge controller (with the lamp symbol), then connect the L– cable.
 Replace the load fuse or switch on the load.
4th step: Final work
 Fasten all cables with strain relief in the direct vicinity of the solar charge controller
(clearance of approx. 10 cm).
4.2.3 Grounding
The components in stand-alone systems do not have to be grounded – this is not standard practice or may be prohibited by national regulations (e.g.: DIN 57100 Part 410:
Prohibition of grounding protective low voltage circuits). Consult the technical manual
for more information.
4.2.4 Lightning protection
In systems subjected to an increased risk of overvoltage damage, we recommend
installing additional lightning protection / overvoltage protection to reduce dropouts.
Consult the technical manual for more detailed information.
5. Operation
The solar charge controller immediately begins operation once the battery is connected
or the external fuse is inserted.
The displays of the solar charge controller show the current operating mode. User
intervention or user settings are not required.
Protection functions
The following integrated protection functions of the solar charge controller ensure that
the battery is handled as gently as possible.
The following protection functions are part of the basic function of the controller:
• Overcharge protection
• Deep discharge protection
• Battery undervoltage protection
• Solar module reverse current protection
The following installation faults do not destroy the controller. After correcting the
fault, the device will continue to operate correctly:
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•
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•
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Protection from solar module short circuits / incorrect solar module polarity
Protection from short circuits at the load output or excessive load current
Protection from battery connection with incorrect polarity
Protection from solar module overcurrent
Protection from device overtemperature
Protection from overvoltage at the load output
Protection from the wrong connection sequence
6. Maintenance
The solar charge controller is maintenance-free.
All components of the PV system must be checked at least annually, according to the
specifications of the respective manufacturers.
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Ensure adequate ventilation of the cooling element.
Check the cable strain relief.
Check that all cable connections are secure.
Tighten screws if necessary.
Terminal corrosion
7. Faults and remedies
Fault
No display
Info LED flashes
red
Cause
Remedy
• battery voltage too low
• the external fuse in the
battery connection cable has
blown.
• battery is not connected
• battery is connected with the
wrong polarity
• battery is defective
• charging interrupted due to
excessive charging current
Load cannot be op- • load output is switched off
due to excessive load current
erated or only for a
short time
+
info LED flashes
red
• load output is switched off
due to short circuit at load
output
• load output is switched off
due to overheating of the
solar charge controller
 pre-charge
 replace
the battery
the external fuse
1. unclamp all connections
. connect a (new) battery with
the correct polarity
3. reconnect the solar module
and loads
charging automatically continues as soon as the charging
current lies within the permissible range
 reduce load current, if necessary switch off or disconnect
loads
 check loads
1. disconnect loads
. correct the cause of the short
circuit
3. reconnect loads
the load output automatically
switches on again once the
solar charge controller has
cooled down
 improve
the cooling air
circulation
 remove
sources
any other heat
 check
Load cannot be
operated
+
• load output is switched
off due to too low battery
voltage
info LED flashes
red
the conditions of use
and the mounting location
the load output automatically
switched on again as soon as
the battery voltage lies within
the permissible range
 pre-charge
the battery
 equip
loads directly connected to the battery with
deep discharge protection
+
red battery LED
flashes
 check
the battery and replace
if necessary
Load cannot be
operated
+
info LED flashes
red
+
• load output is switched off
due to excessive battery
voltage
• incorrect grounding
• external charging source is
not voltage-limited
2. green LED
flashes
Load cannot be
operated
the load output automatically
switched on again as soon as
the battery voltage lies within
the permissible range
 check the grounding
 check the external charging
source
 if
• defective load or installation
error
necessary, switch off external charging sources
 connect load correctly
 replace load
+
info LED illuminates green
Battery is not
charged
Battery display
jumps quickly
• solar module not connected
• solar module connected with
incorrect polarity
• short circuit at solar module
input
• incorrect solar module
voltage
• solar module defective
• large pulse current
• battery is defective
 connect
the solar module
the solar module
with the correct polarity
 correct the cause of the short
circuit
 use a solar module of the
specified voltage
 replace the solar module
 tune the current consumption to match the battery
capacity
 replace the battery
 connect
8. Technical data
Solar charge controller
10 A
15 A
20 A
30 A
Max. module input short circuit
current at 50 °C
10 A
15 A
20 A
30 A
Max. load output current at 50 °C
10 A
15 A
20 A
30 A
Terminal size (fine/single wire)
16/25 mm² = 6/4 AWG
Weight
345 g
Dimensions l x w x h
187 x 96 x 45 mm
Enclosure protection class
IP 32
12 V / 24 V
System voltage
–25 °C ... +50 °C
Ambient temperature allowed
Max. voltage of Solar collector
47 V DC
Temperature compensation
–4 mV/K/Zelle
12-V-system
24-V-system
Permissible battery voltage
range *
9 - 17 V
17,1 - 34 V
Deep discharge warning
(SOC/LVW)
< 40 % /
11,7 V ~ 12,3 V
< 40 % /
23,4 V ~ 24,6 V
Deep discharge protection
(SOC/LVD)
< 30 % /
11,2 V ~ 11,6 V
< 30 % /
22,1 V ~ 23,2 V
Reconnection set point (SOC/LVR)
> 50 % /
12,4 V ~ 12,7 V
> 50 % /
24,8 V ~ 25,4 V
End of charge voltage (float)
13,9 V
27,8 V
Boost charge voltage (boost)
14,4 V
28,8 V
Equalisation charge (equal)
14,7 V
29,4 V
NOTE:
Technical data that varies from the above is given on a device label. Subject to change
without notice.
*If the battery voltage is less than 9 V, the controller switches off and cannot recharge
the battery itself, even if sufficient power is available from the module.
9. Legal guarantee
According to the German legal requirements, for this product the customer has a
2 year legal guarantee.
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 commissioning, incorrect or negligent handling, improper transport, excessive loading, use
of improper equipment, faulty construction work, unsuitable construction location or
improper operation or use. Legal guarantee claims shall only be accepted if notification
of the fault is provided immediately after it is discovered 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
particular 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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