PHOTOVOLTAIK

- PHOTOVOLTAIC - PHOTOVOLTAIQUE - FOTOVOLTAICA

Operating instructions
Solar Charge Controller
8 A / 12 A / 20 A / 30 A

UK
716.140 | 07.50
Contents
1. Safety instructions and exclusion of liability.........................................................2
2. Charge controller with fuzzy logic........................................................................3
3. Configuration.......................................................................................................4
4. Installation............................................................................................................6
5. Operation.............................................................................................................8
6. Maintenance.........................................................................................................9
7. Malfunctions......................................................................................................10
8. Legal Guarantee.................................................................................................10
9. Technical data.....................................................................................................11
10. Protective functions of the controller.................................................................11
11. Charge controller schematic diagram.................................................................12

1. Safety instructions and exclusion of liability

1.1. Safety instructions are identified as follows:
• In this manual, safety instructions for personal safety are identified with this
symbol.
• Instructions which relate to the functional safety of the system are in bold type.

1.2. General safety instructions

For your own safety, the following points must be observed during installation:
• When laying cables, ensure that no damage occurs to any of the
constructional fire safety measures present in the building. There are more
detailed instructions in 4.4. “System wiring”.
• The PV components may not be installed and operated in rooms where highly
flammable mixtures, e.g. from gas bottles, paint, lacquer, solvents etc., may be
present!
• Do not store any of the mentioned mixtures in rooms in where PV components
are installed!
• Avoid sparking when working on the system!
• Solar modules generate electricity under incident light. The full voltage is pre-
sent, even when the incident light levels are low. Work carefully and observe the
appropriate safety precautions.
• During assembly and electrical connection in the DC circuit of the photovoltaic
system, voltages of up to 50 V may occur. You should therefore never touch non-
isolated conductor ends! Use well isolated tools only!
• Do not use measurement equipment you know to be damaged or defective! The
charge controller‘s constructive protective measures can deteriorate if the extensi-
on module is not operated as specified by the manufacturer.
• Factory labels and markings may not be altered, removed or rendered unreadable.
• Impeding the factory-installed ventilation may result in overheating and failure
of the device. Do not cover ventilation openings and cooling elements.
• All work must be carried out in accordance with the national and local electrical
regulations!
• If the device is installed abroad, information on rules and protective measures
must be obtained via the corresponding institutions/authorities.
• Keep children away from the PV system!

1.3. About this manual

This manual describes the functions and installation of a solar charge controller in a PV
system with battery bank. The corresponding manufacturer‘s installation manual must
be observed when installing the remaining components, e.g. solar modules and battery
bank. Before you start work, please read:
• “Assembling the charge controller“, sections 4.1 - 4.4
• Before assembly, ensure that all preparatory measures have been taken.
• Do not start assembly until you are sure that you have understood the technical
details in the manual.
• Perform the work only in the order prescribed by this manual!


• The manual must also be available to third parties for all work performed on the system.
• This manual is a component of the charge controller and must be included with it
when sold on.

1.4. Exclusion of liability

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
charge controller. Improper installation of the system may result in damage to property
and, as a result, to bodily injury. Therefore, we assume no responsibility and liability for
loss, damage or costs which result or are in any way related to incorrect installation,
improper operation and incorrect use and maintenance. Similarly, we assume no
responsibility for patent right or other right infringements of third parties caused by
usage of this charge controller. The manufacturer reserves the right to make changes to
the product, technical data or assembly and operating instructions without prior notice.

2. Charge controller with fuzzy logic

2.1. Overall function of the charge controller in the PV system
The charge controller is used in PV power supplies with battery bank for the hobby and
leisure, residential, business, commercial and small company areas. The charge con-
troller monitors the charge status of the battery, controls the charging process and the
connection/disconnection of the loads. This allows the battery use to be optimised and
its service life to be significantly extended. The charge controller is set for lead batteries
with liquid electrolyte on delivery and can be switched to a setting for batteries with so-
lid electrolyte. The charge controller can be used for all solar modules to the maximum
connection value of the module short circuit current.

2.2. Monitoring and control functions

• SOC calculation
Using a special new algorithm, the controller can „learn“ the characteristic curve of the
battery. After this learning phase, the SOC charge status of the battery is indicated with
an average precision of approx. 90 %. This charge status is the basis for most control
and monitoring functions.
• Overcharge protection
Frequent overcharging damages the battery bank. The charging process and the over-
charge protection are therefore controlled by a new hybrid actuator with pulse-width
modulation to guarantee gentle charging of the battery.
• Voltage recognition
A special measurement process renders battery sensor lines. The voltage drop on the
battery line is compensated out after the first full charge.

LED 1 (Info) for ope- LED 2 (Battery) for charge status,

rating status and fault load shedding and early warning
messages

Plug-in fuse:
8 A controller: 10 A
12 A controller:15 A
20 A controller: 20 A
Integrated tempe- 30 A controller: 30 A
rature sensor Connection terminals

Figure 1


• Cyclical charging (lead and gel)
The charge controller raises the end-of-charge voltage for approx. 1 hour for the next
charging cycle after the SOC falls below 70 % (12.4 V).
• Equalizing charge (lead only)
When the charge status (SOC) falls below 40 % (11,7 V) equalizing charging is activa-
ted. During this stage, the end-of-charge voltage is raised for approx. 1 hour; the elec-
trolyte which prevents acid stratification is mixed and thus extends the service life of
the battery bank. This equalizes all cells and extends the service life of the battery bank.
• Monthly charging
Depending on the setting (lead or gel), the corresponding increase of the end-of-charge
voltage is maintained over 1 hour every 30 days.
• Temperature tracking of the end-of-charge voltage
As the battery temperature increases, the optimum end-of-charge voltage of lead-acid
batteries decreases. At high battery temperatures, a constantly set end-of-charge
voltage leads to uncontrolled gassing. Temperature tracking reduces the end-of-charge
voltage at high temperatures and raises them at low temperatures. Temperature tra-
cking with the sensor integrated in the solar charge controller also functions for cyclical
charging and equalizing charging. The end-of-charge voltage is never raised above 15 V
in order to protect the loads (e.g. equalizing charging at low temperatures).
• Display
Two LEDs provide information on the operation mode of your PV system. LED 1 (Info
LED) shows the controller status, LED 2 (Battery LED) shows the battery status.
• Deep discharge protection
Deep discharge causes your battery to lose capacity due to sulphation. The charge
controller deep discharge protector disconnects the loads at SOC < 30 % (11.1 V). The
loads are automatically reconnected at a charge status of 50 %.

3. Configuration
3.1. Adjusting the charge controller
The solar charge controller automatically adjusts to the system voltage (12 V/24 V)
when it is installed. The controller is set for use with lead batteries with current charge
status calculation on delivery. This must only be changed in the following cases:
• Direct connection of a main load to the battery (see 3.3)
• Use of a gel battery (see 3.4)
• Activation of the night light function (see 3.5)

The charge controller is set using short circuit plugs (“jumpers”) which connect two
adjacent contact pins to one another. These are at the top left of the PCB. (Figure 2)

Figure 2: Jumper

4
3.2 Basic setting
Equalization charging is activated in the charge controller on delivery, i.e. it is optimised
for batteries with liquid electrolyte. Equalization charging is generally deactivated for
batteries with solid electrolyte. Follow the instructions of the battery manufacturer!

black 2   1 Basic setting

blue
4   3
6   5
red 8   7
10   9

3.3 Direct connection to the battery

If other chargers or an inverter are connected to the battery, the charge status is no lon-
ger displayed correctly. The controller can be switched to voltage-controlled regulation,
just like standard products. After this is changed, only the battery voltage is evaluated
to determine the charge status. All functions are activated via voltage levels, including
the charge status display.
LEDred = 10.8 V
LEDyellow = 12.0 V
LEDgreen = 13.2 V

The charge status LED functions as a colour multimeter in this setting.

2   1 Direct connection to the

battery
4   3
6   5
2  1 Tip: For storage, connect jum-
8   7
4  3 pers which are not required
10   9
6  5 to one pin only.

Change the red jumper from 7/8 to 5/6. The blue jumper on 4/6 cannot stay in the
factory setting and must be repositioned as described in the “Selecting the battery”
paragraph.

3.4 Selecting the battery

The following jumper settings are required depending on the battery used and the
charge controller:

Lead battery Gel battery

2   1 2   1
SOC setting 4   3 4   3
6   5 6   5
8   7 8   7
10   9 10   9

2   1 2   1

Voltage setting
4   3 4   3
6   5 6   5
8   7 8   7
10   9 10   9

Lead: Position 3/4 may Gel: When switching to

not be occupied. To do using gel batteries, the
so, either remove the blue blue jumper must be
jumper or place it on 4/6 changed from 4/6 to 3/4.
(factory setting).


3.5 Night light function
If the controller is used in lighting systems, the so-called night light function can be
programmed. If this function is activated, all loads are connected at night and discon-
nected during the day. The deep discharge protector remains activated.
Remove the jumper which connects contact pins 1/2 to activate the night light function.
Store the short circuit plugs (jumpers) safely so that you can return the controller to the
basic setting!

2   1 Night light function

4   3
6   5
8   7
10   9

If you do not wish to attempt to configure the controller yourself, please

contact your specialist dealer. No liability can be accepted for damage of
any kind caused by an incorrectly set charge controller!

4. Installation
4.1. Choose a suitable location
Do not install and operate PV components in rooms where highly flamma-
ble gas mixtures can occur!
Explosive oxyhydrogen gas can form near the battery. Ensure that the area
around the battery is well ventilated and avoid sparking!
Observe the regulations for batteries!

The following must be observed in particular:

• DIN VDE 0510 Part 2, sections
- 7 Precautions against explosion hazard
- 8 Precautions against dangers from electrolyte
- 9 Storage
• National Electric Code with article 690
Choose the installation location in accordance with the following criteria:
• Protect the charge controller from direct weathering
• Avoid direct exposure to sunlight and heating from adjacent devices
• Ensure that the device is not subject to dirt or moisture
• Install it as close to the battery as possible (safety clearance at least 30 cm)

Solar modules Battery Load

Figure 3: Overview of connections


4.2. Securing the charge controller
When securing the charge controller, ensure that the cooling element is well ventilated:
• Install the charge controller so that the cable openings are at the bottom
• Ensure that no objects are within the 100 mm clearance space above and below the device
• Secure the charge controller appropriately: Mount the charge controller to the wall
using the holes in the housing (cooling element) with screws. The charge controller is
designed without strain relief, so that the conductor cross-section can be adapted for
the local conditions. For this reason, strain relief (e.g. cable clips) must be put in place
approx. 100 mm below the controller before the cable looms can be distributed to the
individual components.

4.3. Preparing the wiring

Ensure that the diameter of the wires matches the power output of the controller. The
values of the following table specify the minimum cross-sections required from the
controller to the module distributor box (approx. 10 m), to the battery (approx. 2 m)
and to the load distributor socket (approx. 5 m):
Controller Load Cross-section AWG Isolation
8A 8A 6 mm² 10 85 °C
12 A 12 A 10 mm² 8 85 °C
20 A 20 A 10 mm² 8 85 °C
30 A 30 A 16 mm² 6 85 °C

Before you start wiring ensure that

• the batteries to be used are suitable and correctly connected (check the system
voltage)
• the maximum solar power of the solar generator does not exceed the connection
value of the charge controller

4.4. Wiring
• Solar modules generate electricity under incident light. The full voltage
is present, even when the incident light levels are low. Fasten a light-
proof cover securely over the solar modules with adhesive tape. The
cover allows the voltage level of the modules to be reduced to zero. The
voltage level of the solar modules may never be reduced to zero by short
circuiting them.
• Use well isolated tools only!
• Never touch open conductor ends!
• Isolate any unisolated conductor end which is not connected immediately!
• Only work when the floor below is dry! The components (solar modules, wires
etc.) may not be wet or moist on installation!
• Ensure that the polarity is correct when wiring the device!

n 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). See point 10 for further
information.

n Cutting to size
All conductors must be cut to size before connection:
• Shortening
• Remove isolation on both sides and squeeze core end sleeves open if necessary
• Cover the free conductor ends which are not to be connected immediately with
isolating tape
• Mark the end of each conductor:
- Module cable: M+, M-
- Battery cable: B+, B-
- Load connection cable: L+, L-
Connect the module and string cables to the connection sockets of the PV modules only
in accordance with the manufacturer’s instructions.
Wire the device in the following order to avoid malfunctions:

 Battery  Modules  Load


n Connecting the battery bank to the charge controller
• Remove the fuse in the controller
• Wire the battery connection cable (A+, A-) in parallel between the
charge controller and the battery bank.
• Connect the battery connection cable to the terminal pair of the
charge controller. Ensure that the polarity is correct.
• Fit holders for external (floating) fuses* to the battery connection
cable close to the battery pole:
8 A controller: 10 A
12 A controller: 15 A
20 A controller: 20 A
30 A controller: 30 A
Do not insert the fuse yet.
• Connect battery connection cable A+ to the plus pole of the battery.
• Connect battery connection cable A- to the minus pole of the battery.
• Insert the fuse
*) Not included

n Connecting the solar generator to the charge controller

• Connect the module connection (M+, M-) to the screw-type termi-
nals of the charge controller. Ensure that the polarity is correct.
• Only connect solar generators as energy sources (no power supply
units, diesel or wind generators).

n Connect the loads

• Protect every load circuit with a fuse.
• Disconnect all loads before connecting the load conductor (remove
the fuse) to prevent sparking.
• Connect the load conductor to the screw-type terminals of the
charge controller. Ensure that the polarity is correct!
Connect loads, which may not be switched off by the charge control-
ler shedding the load, e.g. emergency light, radio connection, directly
to the battery! This increases the risk of deep discharge, which is no
longer controlled by the charge controller! Protect these loads with a
separate fuse.
Then secure all cables with strain relief in the immediate vicinity of the charge control-
ler. Fit strain relief for the other components also.

5. Operation
5.1. Testing and commissioning
Check the following items after wiring:
• Correct polarity at all connections (cable labels),
• Secure fit of all cable connections,
• Correct function of all strain relief fittings
• Parallel wiring of the battery connection cables
• Tightness of all screw and terminal connections
Starting the system:
 Insert the fuses at the charge controller and battery and wait until the left LED flashes
green (after 2 min at latest)
 Remove the cover of the solar generator. The loads only work when the right LED
lights permanently or flashes rapidly.

5.2. LED operating status displays

• Charge status display (SOC)
The colour of the right LED indicates the charge status of the battery. The colour
changes in ten steps from red (approx. 0 % charge status) to yellow (approx. 50 %) to
green (approx. 100 %).
•Deep discharge warning
When the charge status falls below 40 %, the right LED flashes rapidly (10 x faster than
the left LED) to warn the user of the risk of load deactivation.


• Deep discharge deactivation
The right LED flashes slowly (approximately the same frequency as the Info LED) to
indicate that the deep discharge protector has deactivated the load. The device is
disconnected when the charge status reaches 30 % (LED lights red/yellow). The load is
automatically reconnected when the SOC reaches 50 % (LED lights yellow). The charge
status can also be identified based on the colour while the LED is flashing.
• Information LED
The information LED flashes green during normal operation. A red colour indicates that
there is a fault. The fault can be determined using the table.

Fault descrip- Controller protec- Info LED Reset Technical

tion tive measures data
Normal Everything OK None Green No reset
operation flashing
Surge current Too much load Load deactivated Red-green Switch off or discon- 110 %
load current flashing nect load 1); rectify
fault
reactivate
Surge current Module current Load deactivated Red-yellow Automatic, when sur- 110 %
module too high flashing ge current no longer
present
Overheating Controller Load deactivated Steady red Automatic, when tem- Internal
overheated light perature drops 2) temp.
85 °C
Battery Battery voltage Load deactivated; Yellow Automatic, when 15 V /
overload too high module short- flashing voltage drops 3) 30 V
circuited

Battery Battery voltage Load deactivated Red Automatic, when 10,5 V /

voltage too too low; no flashing voltage increases 21 V
low battery; faulty
fuse
Open-circuit No battery Load deactivated Both LEDs Disconnect solar
operation connected; steady red generator and replace
fuse faulty fuse (see chap. 7.1)
1) The surge current deactivators are emergency functions which protect the controller from irreparable
damage. When sizing the system, ensure that the max. module and load currents permitted are not
exceeded.
2) If the controller overheats, check whether the device is sufficiently cooled and ventilated at the
installation location.
3) The most common causes of battery overloading are charge sources connected directly to the battery.
As a precaution, loads are switched off, as they are often irreparably damaged by excessive voltage!

6. Maintenance
The charge controller is maintenance-free. Inspect the entire PV installation at least
once a year in accordance with the manufacturer‘s specifications.
• Dust controller and cooling element and ensure that the cooling element is sufficient-
ly ventilated
• Check all strain relief fittings
• Ensure that all cable connections are securely fastened
• Tighten screws if necessary


7. Malfunctions
A range of measures protect the charge controller from irreparable damage. In spite
of this, you must take great care to ensure that the charge controller is used properly.
Some malfunctions are indicated via the information LED. However, only faults for
which the system is properly installed can be displayed. If faults other than those
described occur, first check whether the controller is connected to the battery, the
module and the loads with the correct polarity. Then check whether the fuse is faulty.
The controller automatically switches off the load when faults occur.

7.1. Changing fuses

Follow these steps in the correct order to change a fuse:
 Disconnect the solar generator (minus connection) from the solar charge controller.
 Remove the faulty fuse and insert a new one (the left LED flashes green)
 Reconnect the solar generator to the solar charge controller

7.2. Starting after open-circuit operation

If the battery is not connected to the controller (open-circuit operation, fuse faulty, bat-
tery connection interrupted) and the solar module supplies more power than the load
requires, both LEDs light red. If the solar power generated is less than the consumption,
the load is activated periodically. At night, both LEDs are switched off. The controller is
protected against open-circuit operation. However, to guarantee safe start-up after this
open-circuit operation, the following steps are absolutely necessary:
 Disconnect the solar generator (minus connection) from the solar charge controller.
 Remove the fuse and insert it again (restart)
 Connect the solar generator again

8. 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
particular claims for damages due to lost profit, loss-of-use or indirect damages are
excluded, unless liability is obligatory by German law.

10
9. Technical data
Charge controller type 8A 12 A 20 A 30 A
Max. module short-circuit current
8A 12 A 20 A 30 A
at 50 °C

Max. load current at 50 °C 8A 12 A 20 A 30 A

Terminal clamps
16/25 mm² = 4/6 AWB
(fine-wire/single wire)
Weight 420 g
Measurements 188 x 106 x 49
Protection class IP 22
System voltage 12 V / 24 V
Permitted ambient temperature -25 °C...+50 °C
Algorithm data: AtonIC
SOC oriented: Voltage oriented:
Deep discharge warning SOC < 40 % 11,7 V
Load shedding SOC < 30 % 11,1 V
Shift-in SOC > 50 % 12,6 V
Equalization loading (14.7 V) SOC < 40 % 11,7 V
Cyclical loading (14.4 V) SOC < 70 % 12,4 V
End-of-charge voltage 13,7 V 13,7 V

Temperature compensation -4 mV/K/cell -4 mV/K/cell

The voltage must be doubled when used in 24 V systems!

10. Protective functions of the controller

The solar controller has the following protective functions:
• Short circuit at the module.
Electronically protected. The charging process is automatically interrupted.
Measures: Connect the module correctly. The controller automatically continues to work.
• Incorrect polarity of the battery.
Plug-in fuse is triggered.
Measures: Connect the battery with correct polarity. Replace the plug-in fuse, see 7.1.
• Short circuit at the load output and/or surge current.
Electronically protected. Information display flashes red-green (see 5.2).
Measures: Disconnect the load cable and wait until the information display switches
from red-green to green flashing. Reconnect the load cable.
• Surge current, overheating, overload of the module.
Electronically protected. Load is deactivated automatically.
Measures: Wait until a permitted operating status has returned. The controller
automatically reactivates the load.
• Undervoltage.
Electronically protected. Load is deactivated automatically.
Measures: Wait until the battery is sufficiently recharged. The controller automatical-
ly reactivates the load.
• Operation without battery.
Electronically protected. The controller is protected, its functions are limited.
Measures: see 7.2.
• Incorrect polarity of a module.
Electronically protected. The charging process is automatically interrupted.
Measures: Connect the module correctly.

11
11. Charge controller schematic diagram
The following sections only
describe the technical grounding
options. The goal is to maintain
the controller functions. The in-
stalling engineer must note and
observe the national regulations
in the region of use. The loss of
the protective low voltage status
caused by grounding must be
compensated by correspon-
ding isolation measures for
live parts (protection against
direct contact). If the plus side
is selected for grounding, it
can also be used as an earth
for all system components. All
plus conductors are internally
interconnected in any case.
Only one connection can be
grounded from the minus
connections of the module,

battery and load components.

If your solar system already
provides a minus-side earth,
only one component (in this
example, battery-minus) may be
connected to this earth. Connec-
ting to other minus connec-
tions (module or load) bridges
control elements and the fuse.
This causes malfunctions or
even irreparable damage to
the controller. In systems with
preset load–minus–earth (e.g.
grounding antennas) all other
components must be floating.

12