Studer VarioString VS-70 Manuale utente

Studer Innotec SA 2018 V 2.3

4O9P

VarioString

MPPT solar charge controller

User manual

Accessories:

Remote control……………………………………. RCC-02/03

Temperature sensor…....…………………………. BTS-01

External auxiliary relay module...………………. ARM-02

VarioString

VS - 120

48V- 120A

VarioString

VS -70

48V- 70A

Studer Innotec SA

VarioString

2 V 2.3 User manual

Studer Innotec SA

VarioString

User manual V 2.3 3

Contents

1INTRODUCTION ...................................................................................................................................... 5

2GENERAL INFORMATION....................................................................................................................... 5

2.1 About this user manual ....................................................................................................................... 5

2.2Important safety instructions.............................................................................................................. 6

2.3 Conventions.......................................................................................................................................... 6

2.4 Quality and warranty .......................................................................................................................... 7

2.4.1 Exclusion of warranty.................................................................................................................. 7

2.4.2 Exclusion of liability...................................................................................................................... 7

2.5 Warnings and guidelines .................................................................................................................... 8

3MOUNTING AND INSTALLATION........................................................................................................... 8

3.1Storage .................................................................................................................................................. 8

3.2 Unpacking............................................................................................................................................. 8

3.3 Mounting place.................................................................................................................................... 9

3.4 Fixing/Dimensions................................................................................................................................. 9

3.4.1 VarioString VS-120........................................................................................................................ 9

3.4.2 VarioString VS-70....................................................................................................................... 10

3.4.3 Assembling the cooling fan ECF-01....................................................................................... 10

4WIRING ................................................................................................................................................. 11

4.1 Elements of the cable compartment ............................................................................................ 11

4.1.1 VarioString VS-70........................................................................................................................ 12

4.1.2 VarioString VS-120...................................................................................................................... 13

4.2 Connecting the battery ................................................................................................................... 14

4.2.1 Precautions when using the batteries................................................................................... 14

4.2.2 Connecting the battery........................................................................................................... 15

4.2.3 Protection device of the battery ........................................................................................... 15

4.3 Photovoltaic generator (PV) ........................................................................................................... 16

4.3.1 Dimensioning.............................................................................................................................. 16

4.3.2 Serial connection (chain or string) of PV modules ............................................................. 17

4.3.3 Parallel connection of PV module strings............................................................................. 18

4.3.4 Safe use of the photovoltaic modules.................................................................................. 19

4.3.5 Protection devices .................................................................................................................... 19

4.3.6 Cable cross-section and connection ................................................................................... 19

4.3.7 Parallel connection of several VarioString ........................................................................... 19

4.3.8 Extension of an existing installation........................................................................................ 20

4.4 Earthing................................................................................................................................................ 20

4.4.1 Detecting an earthing fault .................................................................................................... 20

4.5 Lightning protection .......................................................................................................................... 21

4.6 Connecting the communication cables ...................................................................................... 21

5POWER-UP OF THE EQUIPMENT........................................................................................................... 22

6DISPLAY SYSTEM................................................................................................................................... 23

6.1 The “SET” button (4) ........................................................................................................................... 23

6.2 “Night” standby indicator (1) .......................................................................................................... 23

6.3 “Charge” cycle indicator (2) .......................................................................................................... 23

6.4 “Error” indicator (3)............................................................................................................................ 24

6.5 Charging current Indicator (5)-(6)-(7)-(8)-(9)-(10) ....................................................................... 24

7BATTERY CHARGING PROCESS........................................................................................................... 25

7.1 General points.................................................................................................................................... 25

7.2 Battery cycle....................................................................................................................................... 25

7.2.1 Bulk phase (1)............................................................................................................................. 25

7.2.2 Absorption phase (2) ................................................................................................................ 25

7.2.3 Floating phase (4) ..................................................................................................................... 25

7.2.4 Equalization phase (3).............................................................................................................. 25

7.2.5 Temperature compensation................................................................................................... 26

7.3 Default battery charge cycle (original settings) ......................................................................... 26

7.4 Recovery after deep discharge ..................................................................................................... 26

8REMOTE ENTRY (AVAILABLE AS FROM SOFTWARE VERSION 1.5.22) ............................................... 27

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9CONFIGURING THE VARIOSTRING(S)................................................................................................. 27

9.1 Configuring the equipment by means of the internal DIP switches ........................................ 27

9.2 Displaying the equipment status using the remote control RCC-02/03.................................. 29

9.2.1 Displaying the status of a single unit system ........................................................................ 29

9.2.2 Displaying the operating mode of the equipment (Info n° 15013,15014,15015).......... 31

9.2.3 Displaying security errors (Info n° 15049)............................................................................... 32

9.2.4 Displaying the values of a multi-unit system ........................................................................ 32

9.2.5 Displaying messages and event history................................................................................ 32

9.3 Configuring the VarioString using the remote control RCC-02/03 ........................................... 33

9.3.1 The real time clock.................................................................................................................... 33

9.4 Description of the VarioString parameters.................................................................................... 33

9.4.1 Convention................................................................................................................................. 33

9.4.2 Parameter access level ........................................................................................................... 34

9.4.3 Organisation of the VarioString configuration menu ......................................................... 34

9.4.4 Basic settings {14000}................................................................................................................ 36

9.4.5 Battery management and cycle {14003}............................................................................. 36

9.4.6 System {14037} ........................................................................................................................... 40

9.4.7 Auxiliary contacts 1 {14070} and 2 {14122}........................................................................... 42

10 ACCESSORIES ...................................................................................................................................... 46

10.1 Remote control and programming centre RCC-02/03.............................................................. 46

10.2 Temperature sensor BTS-01............................................................................................................... 47

10.2.1 Connecting the temperature sensor (BTS-01) ..................................................................... 47

10.3 Auxiliary relay module ARM-02........................................................................................................ 48

10.4 Parallel connection cable ............................................................................................................... 48

11 EQUIPMENTS COMPATIBLE WITH THE VARIOSTRING ......................................................................... 48

11.1 Xtender inverter/chargers................................................................................................................ 48

11.2 Battery status processor BSP- 500/1200.......................................................................................... 48

11.3 Communication module Xcom-232i.............................................................................................. 49

11.4 Communication sets Xcom-LAN/-GSM ......................................................................................... 49

11.5 Communication module Xcom-SMS ............................................................................................. 49

11.6 Multi-protocol communication module Xcom-CAN .................................................................. 49

12 WIRING EXAMPLES .............................................................................................................................. 50

12.1 VarioString + RCC-02 ......................................................................................................................... 50

12.2 Comments on the wiring examples 12.1....................................................................................... 50

12.3 VarioString VS-70 + RCC-02.............................................................................................................. 51

12.4 Comments on the wiring examples 11.3....................................................................................... 51

13 MAINTENANCE OF THE INSTALLATION ............................................................................................... 52

14 PRODUCT RECYCLING......................................................................................................................... 52

15 EU DECLARATION OF CONFORMITY .................................................................................................. 52

16 TROUBLE-SHOOTING............................................................................................................................ 53

17 PARAMETER LIST ................................................................................................................................... 54

18 TECHNICAL DATA ................................................................................................................................ 58

18.1 General specifications...................................................................................................................... 58

18.2 Input (PV generator) ......................................................................................................................... 58

18.3 Output (battery)................................................................................................................................. 58

18.4 Environment ........................................................................................................................................ 59

18.5 Protection ............................................................................................................................................ 59

18.6 Communication ................................................................................................................................. 59

18.7 Compliance........................................................................................................................................ 59

19 INDEX OF PARAMETERS ....................................................................................................................... 60

Studer Innotec SA

VarioString

User manual V 2.3 5

1INTRODUCTION

Congratulations! You are about to install and use a device from the VarioString range. You have

chosen high-tech equipment that will play a central role in the energy production of your solar

electrical installation. The VarioString has been designed to work as a solar battery charger; its

advanced and completely configurable functionalities will guarantee a perfect functioning of your

energy system.

When the VarioString is connected to batteries and photovoltaic panels, it automatically recharges

batteries in an optimum way with all the available solar power. The VarioString VS-120 can be

connected to two strings of PV modules in different configurations (series, parallel, or independent).

This configuration flexibility allows the user to optimise their installation. The accuracy of the Maximum

Power Point Tracking (MPPT) algorithm, the high output and low internal consumption ensure an

optimal valorisation of the energy produced by the PV modules.

The charge profile may be set freely according to the battery type or the operation mode. The

charging voltage is corrected depending on the temperature thanks to the optional external sensor

BTS-01.

The control, display and programming unit RCC-02/03 (optional) allows an optimal setup of the

system and guarantees the user a permanent control over all important parameters for the

installation with a clear display interface. Moreover, it allows recording the system data in order to

analyse later its functioning (data logging).

The parallel operation of several chargers is possible and offers modularity and flexibility enabling an

optimum dimensioning of your system according to your energy requirements.

The VarioString operates as an independent device but is also designed to be included into a Studer

energy system together with the Xtender inverters/chargers, the BSP battery monitor, the control,

display and programming unit RCC-02/03 and all Xcom communication modules. Working together,

these different devices have a synchronised behaviour for a better management of the battery and

of the solar resource.

Please read this manual carefully to ensure the perfect start up and operation of your system. It

contains all necessary information regarding the operation of the VarioString charger. The installation

of such a system requires special expertise and may only be carried out by qualified personnel

familiar with the local standards in force.

2GENERAL INFORMATION

2.1 ABOUT THIS USER MANUAL

This manual contains necessary information and procedures to install, configure, use and

troubleshoot the VarioString solar charge controllers. It does not contain information about

photovoltaic modules (PV) or batteries of various brands that can be connected. For this kind of

information, please refer to the instructions of each specific manufacturer.

It covers the following models and accessories:

MPPT solar charge controller:

VarioString VS-70,

VarioString VS-120

Temperature sensor: BTS-01

External auxiliary relay module: ARM-02

This manual is an integral part of the equipment and must be available for the operator

and/or the installer at all times. Always keep it close to the installation.

Studer Innotec SA

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6 V 2.3 User manual

2.2 IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety instructions. Read carefully the safety and operation

instructions before using the VarioString. Take into consideration all warnings mentioned both on the

equipment and in this manual, strictly following all instructions regarding its operation and use.

This user manual is intended to serve as a guideline for the safe and efficient use of the VarioString.

Anyone who installs or uses a VarioString can completely rely on this user manual and is bound to

observe all the safety instructions and indications here in.

The installation and commissioning of the VarioString must be entrusted to qualified personnel. The

installation and use must comply with the local safety instructions and standards in force in the

country.

2.3 CONVENTIONS

This symbol is used to indicate safety instructions which, if not followed, could result in serious

personal injury or death to the operator or the user.

This symbol is used to indicate a general danger for the user and/or a risk of material

damage and/or the cancellation of the guarantee.

This symbol is used to indicate a procedure or function that is important for a safe and

correct use of the equipment. Failure to respect these instructions may lead to the

cancellation of the guarantee or to a non-compliant installation.

This symbol placed on the product indicates that its surfaces may reach temperatures

higher than 60°C.

This symbol placed on the product indicates that its use must follow the instructions in the

user’s manual.

In general, values important for the operation of the equipment (for example: battery voltage during

absorption) are not mentioned and the parameter number is indicated in the following format:

{xxxxx}. The value of the parameter can be found in the table chap. 16.

In most cases, these values can be modified with the remote control RCC-02/03 (see chap. 10.1).

The parameter table available at the end of this manual (chapter 16) must be kept updated

in case the parameters are modified by the operator or the installer.

If an authorised person modifies a parameter not included in the list (advanced

parameters), the number of the modified parameter(s), the specifications of the

parameter(s) and the new value set are to be indicated at the end of the table.

All values that are not followed by a parameter number may not be modified.

All digits and letters in brackets or in square brackets in the text of this manual refer to items

represented in illustrations with a circle.

Studer Innotec SA

VarioString

User manual V 2.3 7

2.4 QUALITY AND WARRANTY

During production and assembly of the VarioString, each unit undergoes several checks and tests

which strictly comply with established procedures. The manufacturing, assembling and testing of

each VarioString are completely carried out in our factory in Sion (CH). The equipment warranty

depends upon the strict application of the instructions in this manual.

The VarioString MPPT solar charge controller has a 5-year warranty (starting from the date of

production against material and manufacturing faults). A defective product will either be repaired

or replaced at the discretion of Studer Innotec.

2.4.1 Exclusion of warranty

No warranty claims will be accepted for damages resulting from handling, use or treatment that are

not explicitly mentioned in this manual. In particular, damages arising from the following causes are

excluded from the warranty:

Voltage higher than 600V across PV terminals (independent or parallel configuration) or

higher than 900V (series configuration).

Accidental presence of liquids in the equipment or oxidation due to condensation.

Damage resulting from falls, mechanical shocks or permanent or excessive vibrations.

Modifications carried out without the explicit authorisation of Studer Innotec.

Nuts or screws that have not been tightened sufficiently during the installation or

maintenance.

Damage due to atmospheric surge voltage (lightning).

Damage due to inappropriate transportation or packaging.

Disappearance of original identification marks.

Never take off or damage the rating plate showing the serial number. It enables to check

and follow-up the data specific to each equipment and is vital for any warranty claim.

2.4.2 Exclusion of liability

The installation, commissioning, use, maintenance and servicing of the VarioString cannot be subject

of monitoring by Studer Innotec. Therefore, we disclaim all responsibility and liability for damage,

costs or losses resulting from an installation that does not comply with the instructions, a faulty

operation or inadequate maintenance. The use of Studer Innotec equipment is in any case under

the responsibility of the customer.

This equipment is neither designed nor guaranteed to supply installations used for vital medical care

nor any other critical installation entailing potential risks of important damage to people or to the

environment.

We assume no responsibility for the infringement of patent rights or other third parties rights resulting

from the use of the MPPT solar charge controller VarioString.

Studer Innotec reserves the right to make any modifications to the product without prior notification.

Studer Innotec is not liable for incidental, direct or indirect damages of any kind, including any profit

loss, revenue loss or damages caused to equipment or goods due to defective equipment.

Studer Innotec SA

VarioString

8 V 2.3 User manual

2.5 WARNINGS AND GUIDELINES

The installation and commissioning of the VarioString must be entrusted to skilled and qualified

personnel perfectly aware of the safety precautions and local rules in force. All elements connected

to the VarioString must comply with the laws and regulations in force.

HIGH-VOLTAGE DC INSIDE THE CHARGE REGULATOR: DANGER OF DEATH

When the VarioString is in operation it generates voltages that can be potentially lethal (up

to 600V (VS-70) and 900V (VS-120)). Any work on or close to the installation must only be

carried out by thoroughly trained and qualified personnel. Do not try to carry out ordinary

maintenance on this product yourself.

While working on the electrical installation, it is important to make sure that the source of

DC voltage coming from the battery as well as the source of DC voltage coming from the

photovoltaic generator, have been disconnected from the electrical installation.

Even when the VarioString has been disconnected from the power sources, a potentially

dangerous voltage may remain at the terminals. To eliminate this you have to wait for at least

5 minutes in order to allow the electronics to discharge. The task can then be carried out safely.

No person is authorized to proceed with any change, modification or repair of the equipment without

prior written authorisation from Studer Innotec. Only original parts should be used in authorised

modifications or replacements.

Respect the maximum rated specifications of the equipment indicated on the type label.

The VarioString can be installed at altitudes up to 3000m. For installations at higher

altitudes, please contact Studer Innotec SA.

The VarioString is in overvoltage category II, in accordance with the norm IEC/EN 62109-

1:2010 that considers all solar generators as being in overvoltage category II.

3MOUNTING AND INSTALLATION

The wiring and connection of the installation must be carried out only by perfectly qualified

personnel. The installation material such as cables, connectors, distribution boxes, fuses,

etc., must be appropriate and comply with the laws and regulations in force for the

application in question.

3.1 STORAGE

The equipment must be stored in a dry environment at an ambient temperature between -20°C and

60°C. Place the equipment at its mounting place at least 24 hours before commissioning in order to

avoid thermal shocks and condensation problems.

3.2 UNPACKING

When unpacking, check that the VarioString has not been damaged during transportation and that

all accessories listed below are present. Any fault must be immediately reported to the product

distributor or the contact mentioned at the back of this manual.

Carefully check the packaging as well as the VarioString.

Contents in the VarioString box:

VarioString

Installation and operation manual

Cable-glands for the battery cables

Solar cable connectors, 1 pair (VS-70) and 2 pairs (VS-120)

Communication cable

Studer Innotec SA

VarioString

User manual V 2.3 9

3.3 MOUNTING PLACE

The mounting place for the VarioString is particularly important and must fulfil the following criteria:

Indoors

Protected from water and dust in a location without condensation.

Protected from any unauthorized person.

In a place where the relative humidity does not exceed 95%

In a place where the ambient temperature is between -20 and 55°C

In mobile applications, it is important to select a mounting place that ensures no vibration.

Protected from direct solar radiation or heat sources.

It should not be mounted directly above the battery or in a cabinet with the battery

The ventilation vents should be clear at all times and at least 20 cm from all obstacles that

could alter the ventilation of the device.

Given the norm IEC/EN 62109-1, the degree of pollution in the installation area should be at

maximum PD2 for the VS-120 and PD3 for the VS-70.

The support for the VarioString and the environment in which it is contained should not be

flammable.

The presence of a heat source may significantly reduce its rated power. Similarly, insufficient

ventilation may lead to the overheating of some internal components of the equipment. In this case,

the device will automatically limit its power as long as this abnormal situation persists.

As far as possible, reduce exposure to sudden temperature variation: important heat variation may

create undesired and harmful condensation inside the equipment.

3.4 FIXING/DIMENSIONS

The VarioString is a heavy equipment (5.5 kg (VS-70) and 7.5 kg (VS-120)) and must be mounted

to a support (wall) designed to bear such a load. It is imperative to ensure a complete and safe

fastening of the equipment. If simply hung, it may fall down and cause severe damages.

The VarioString must be installed vertically. A distance of at least 5cm between the units and/or 20cm

around the equipment is required to guarantee adequate ventilation.

If the VarioString is installed in a closed cabinet, it must have sufficient ventilation to guarantee that

the ambient temperature is kept within the operating limits of the VarioString.

In motor vehicles, or when the support undergoes significant vibrations, the VarioString is to be

mounted on anti-vibration elements.

3.4.1 VarioString VS-120

Upper support screw: screw into the wall a 6-8 mm diameter screw without washer until there is 1.6

mm between the head of the screw and the wall. Hang the device from the screw. If deemed

Studer Innotec SA

VarioString

10 V 2.3 User manual

necessary, the upper support screw can be fully tightened after hanging the device. In theory this is

only necessary in mobile applications. To access the upper support screw to fully tighten it, remove

the upper plastic grate.

Lower support screws: remove the lower plastic grate which gives access to the cabling

compartment. Carefully fix the device to the support with two screws (6-8 mm in diameter) using the

two mounting holes located at the bottom left and right of the cabling compartment.

3.4.2 VarioString VS-70

The VS-70 enclosure is fitted with a support plate to be mounted on

the back of the case using 4 screws M6, 8 mm long, and washers (see

fig. hereafter), before wall mounting. Mount it vertically with the

cable-glands downward.

The external cooling fan can be installed before or after the

equipment has been mounted on the wall.

The 4 mounting screws of the enclosure must be completely

tightened with a torque of (>3Nm - 10Nm<) in order to guarantee the

IP 54 protection index. Any unused cable glands should be closed in

a way that guarantees at least the same level of protection.

3.4.3 Assembling the cooling fan ECF-01

The VarioString VS-70 is supplied with an external cooling fan module (ECF-01). This module can be

installed before or after mounting the VarioString VS-70, on the wall.

This fan has a degree of protection IP54 and can be exposed to water spray without damage.

However, do not expose it to dirty water splashes in order to prevent mud or similar particles from

blocking the mechanism.

Assembly instructions:

1. Remove the plastic cap

and insert the connector

until the click sound.

2. Position the cover by

inserting the screws.

3. Fully tighten the two

screws.

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