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Studer Innotec SA

VarioString

User manual

3

Contents

INTRODUCTION ...................................................................................................................................... 5

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

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

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

Conventions .......................................................................................................................................... 6

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

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

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

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

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

Storage .................................................................................................................................................. 8

Unpacking ............................................................................................................................................. 8

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

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

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

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

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

WIRING ................................................................................................................................................. 11

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

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

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

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

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

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

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

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

Dimensioning .............................................................................................................................. 16

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

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

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

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

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

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

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

Earthing ................................................................................................................................................ 20

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Summary of Contents for VarioString VS-120

Page 1: ...18 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 ...

Page 2: ...Studer Innotec SA VarioString 2 V 2 3 User manual ...

Page 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 2...

Page 4: ...ary 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...

Page 5: ...se 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 ...

Page 6: ...ate 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 ...

Page 7: ...een 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 E...

Page 8: ...isation 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 ...

Page 9: ...on 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...

Page 10: ...he 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 coolin...

Page 11: ... the battery positive pole VS 70 M6 5Nm torque PG 16 10 14mm VS 120 M10 8Nm torque PG 21 13 18mm This connection must be done using a protection and disconnection device if the pole has not been earthed For mounting of the internal fuse refer to sect 4 2 2 2 Terminal to connect the battery negative pole VS 70 M6 5Nm torque PG 16 10 14mm VS 120 M8 8Nm torque PG 21 13 18mm This connection must be do...

Page 12: ... be defined by programming by the closing of a dry contact or by the presence of a voltage across these terminals 13 Jumper for programming of the remote entry See sect 8 p 27 in fig 4 1 1 and 4 1 2 By default they are positioned at A 1 2 and B 2 3 14 Battery protection fuse VS 70 Fuse 100A 80V sect 4 2 2 2 VS 120 Fuse CF8 150A 58V sect 4 2 2 1 4 1 1 VarioString VS 70 ...

Page 13: ...Studer Innotec SA VarioString User manual V 2 3 13 4 1 2 VarioString VS 120 ...

Page 14: ...ately consult a doctor The battery acid can be neutralized with baking soda among other things A sufficient quantity of baking soda should be available for this purpose Particular care is required when working close to batteries with metal tools Tools such as screwdrivers open ended spanners etc may cause short circuits Sparks created by short circuits may cause the battery to explode Therefore th...

Page 15: ...as possible to the battery The recommended cross section of battery cable is valid for lengths up to 3m Beyond this length it is recommended to oversize the section of the battery cables Any other sources or loads existing on the battery must be connected using their own protection devices Never connect them to the protection device s of the VarioString A battery voltage higher than 75V can cause ...

Page 16: ...arallel must be carried out according to the voltage and current limits of the VarioString solar charge controller The possible operating range of the VS 70 is illustrated in the graph below The whole solar system must be installed according to protection class II The capacitor banks inside the VS 120 hold a DC voltage for several minutes after the PV input is disconnected It is necessary to wait ...

Page 17: ...hould be connected to the pole of the PV generator and a bridge should be made between the entries 4 and 5 The open circuit voltage of the string must be lower than 600V under any temperature and irradiation conditions A 10 to 20 margin is recommended in order to cover these unknowns When the two inputs are used in series on the VarioString VS 120 the maximum open circuit voltage should not surpas...

Page 18: ...llel is equal to 3500W divided by the power of a string and rounded down to the nearest whole number see table below For example with 12 modules of 110W in series 3500 1320 2 65 2 strings 2640W can be connected in parallel If both VarioString inputs are connected in parallel for the strings of 12 modules in series mentioned above 5 strings could be connected in parallel 7000 1320 5 3 5 The PV gene...

Page 19: ...rioStrings as necessary can be connected in parallel on the same battery bank according to the battery capacity Each will have its own independent solar generator connected in independent parallel or series configuration and include its own disconnection and protection device to the battery Up to 15 VarioStrings can be synchronized and interconnected to the same communication bus see chap 4 6 on a...

Page 20: ... force 4 4 1 Detecting an earthing fault The choice of earthing system for the DC circuit is an important factor for the individuals safety Once the decision is made the VarioString can check the continuity of the earth connection In case of failure of this connection the LED 3 see sect 6 lights up indicating the fault A permanent message requiring a validation is displayed on the RCC if present T...

Page 21: ...d the protection devices of power sources and loads should be open to complete the cable connection and positioning of the termination switches of all the devices connected to the communication bus The maximum total length of the communication bus is 300m Due to a line voltage drop it is recommended to install only one RCC module at the end of a 300m line or a max of 2 modules at the end of a 150m...

Page 22: ...tomatic detection of the cabling type of the PV generators In the case that the cabling configuration is entered manually the datalog is activated immediately It is imperative that the closing cover for the connection compartment is installed and screwed tight before energizing the installation There are dangerous voltages inside the cable compartment If special configurations or settings are requ...

Page 23: ...s indicator flashes when there is a PV voltage but it is insufficient to charge the batteries at the beginning or at the end of the day In order to save the battery power the VarioString charger turns off and goes in standby mode when this indicator lights up or flashes It will then consume less than 1W The charger automatically switches on again when the sun starts shining and PV voltage goes bac...

Page 24: ... 900V in series The equipment will stop or won t start See also chap 4 3 2 Blinks 6x Software incompatibility in a system The different parts of the system s equipment must have the same software version to function properly Proceed with the update following the procedure in the RCC 02 03 manual Blinks 7x Not used Blinks 8x The PV current is higher than the set value of the max operating limit The...

Page 25: ...not reached if the generator power is not sufficient because of its dimensioning solar power silicon temperature crystalline cell or because the ambient temperature is excessive or the ventilation is insufficient 7 2 2 Absorption phase 2 The absorption phase can be disabled by parameter 14008 The maximum voltage that can be reached will be the floating voltage 14005 It is the case when charging a ...

Page 26: ...commendations of your battery supplier Incorrect values which do not comply with the manufacturer s instructions can lead to a premature ageing and even the destruction of the batteries For more information contact your battery supplier who will inform you on the values to be applied for their products 7 2 5 Temperature compensation If a BTS 01 or BSP 500 1200 temperature sensor is used the voltag...

Page 27: ...03 described in the following chapter 9 1 CONFIGURING THE EQUIPMENT BY MEANS OF THE INTERNAL DIP SWITCHES Basic settings of the device can be entered manually with the aid of the DIP switch This setting is only possible if the parameter 14174 permits it This parameter is authorised by default The following table provides an overview of the functions associated with each position of the DIP switch ...

Page 28: ... by parameter 14036 When several VarioStrings are interconnected communication and linked to the same battery differences in production power are normal especially in the following cases The units are in voltage regulation phase absorption equalization floating and in this case the current distribution may be very uneven This situation is normal and has no influence on the system efficiency The eq...

Page 29: ...tiple VarioStrings VS 70 VS 120 1 Activation of DIP switch of authorized by 14174 Identical for all 2 to 4 Configuration of battery cycle Identical for all 5 to 8 5 à 6 Reserved 7 to 8 Configuration of cabling of PV modules Can be different Only the configuration of the cabling of the MPPT inputs can be different from one VarioString to another The battery charge cycle should be configured the sam...

Page 30: ...bsp 15016 Cd Ah Production PV in Ah for the current day 15017 Ed kWh Production PV in kWh for the current day 15018 Ed1 kWh Production PV1 in kWh for the current day 15019 Ed2 kWh Production PV2 in kWh for the current day 15020 kWhR kWh Produced PV energy resettable counter 15021 kWh1 kWh Produced PV1 energy resettable counter 15022 kWh2 kWh Produced PV2 energy resettable counter 15023 MWhT MWh To...

Page 31: ...t the selected relay field press ESC 9 2 2 Displaying the operating mode of the equipment Info n 15013 15014 15015 Night the solar generator voltage or luminous intensity is not enough to start the equipment When this indication appears during the day it means a generator fault wiring Charge the charger operates normally at the maximum power point of the solar generator Charge U the VarioString op...

Page 32: ...t starts again when the temperature drops back to a normal value Halted 020 Battery overvoltage the battery voltage is higher than 68V The VarioString turns off It starts again when the voltage returns to a normal value Warning 081 Earthing fault the battery earthing does not anymore match the selection made by parameters 14040 14041 and 14042 which establishes the type of earthing to be checked T...

Page 33: ...clock The VarioString features a real time clock that allows among others to have a correct date and hour for the RCC records This clock must be set using the remote control RCC 02 03 Thanks to an internal battery this setting is retained even when the equipment is disconnected from its voltage source battery or PV 9 4 DESCRIPTION OF THE VARIOSTRING PARAMETERS The parameters of the VarioString can...

Page 34: ...14035 Temperature compensation 3 mV C cell Expert 14004 Floating phase Expert 14005 Floating voltage 54 4 Vdc Expert 14006 Force phase of floating Expert 14007 Absorption phase Expert 14008 Absorption phase allowed Yes Expert 14009 Absorption voltage 57 6 Vdc Expert 14010 Force absorption phase Expert 14011 Absorption duration 120 min Expert 14012 End of absorption triggered by the current No Expe...

Page 35: ... PV wiring type erased from memory Expert 14195 Configuration for VS 70 Expert 14196 Type of PV grounding No control Expert 14180 Type of MPPT algorithm Expert 14197 Type of MPP tracking algorithm PV LSF Expert 14198 PV voltage fixed 500 Vdc Expert 14199 Ratio of PV open circuit voltage 0 7 Inst 14192 Establishment time Algo MPPT 0 sec Inst 14193 Averaging time algo MPPT 0 sec Expert 14200 Remote ...

Page 36: ...oString parameters to be restored to factory settings 9 4 5 Battery management and cycle 14003 The VarioString battery charger is designed to ensure a battery charge as complete as possible The charge process described in detail in chapter 7 2 is managed in 4 successive phases of which only 3 are activated by default Thus the VarioString will carry out only phases 1 bulk 2 absorption and 4 floatin...

Page 37: ...e level 9 4 5 6 2 Force phase of floating 14006 This parameter may be used to force a battery cycle in progress to assume the final values of the floating voltage phase If the battery voltage level is higher the charger momentarily switches out until the new target voltage is reached 9 4 5 7 Absorption phase 14007 During this phase the battery accumulates the last percentages of power to be stored...

Page 38: ...anufacturer regarding this phase In any case make sure that the battery room is adequately ventilated Equalization reduces the battery water level check it regularly 9 4 5 8 1 Equalization allowed 14017 no Determines whether the equalization phase triggered manually or automatically is allowed or not 9 4 5 8 2 Force equalization 14018 Use this parameter to manually start the equalization phase It ...

Page 39: ...s below this value 9 4 5 8 10 Equalization before absorption phase 14019 yes This parameter determines if during the charge cycle the equalization will take place before or after the absorption phase By default the equalization phase is carried out before the absorption phase A equalization voltage B absorption voltage C floating voltage 9 4 5 9 New cycle 14027 Usually batteries are charged during...

Page 40: ...tery terminals 9 4 6 3 Configuration for VS 120 14194 9 4 6 3 1 Type of PV grounding 14041 no control This parameter allows the VarioString to constantly verify the state of the PV grounding connection during its use in series or parallel mode In the event of an error the VarioString will turn on a LED indicator light 3 It is possible to ground either of the PV terminals 9 4 6 3 2 Type of PV1 grou...

Page 41: ...rithm used by the VarioString to establish its operating point P O Maximum Power Point MPP search algorithm This algorithm is fully automatic and searches the MPP of your system OC ratio With this mode the VarioString makes an open circuit voltage measurement once every 5 minutes and fixes the working voltage at a point proportional to the measurement The measurement lasts 2 seconds Ratio of PV op...

Page 42: ... you wish to measure the energy produced over a given time interval 9 4 6 9 Reset daily solar production meters 14051 and 9 4 6 10 Reset daily min max 14052 These parameters allow you to reset to zero the different corresponding daily meters This could be useful if you wish to know these values precisely over a specific period of time 9 4 6 11 Restore default settings 14067 See basic parameters ch...

Page 43: ...d restrictions define the deactivation of the relay 9 4 7 2 Combination of the events for the auxiliary contact 14072 14124 first active OR This parameter defines how various events intended to activate the auxiliary contact are combined The contact can be activated either by a single event OR function or by all events being fulfilled at the same time AND function 9 4 7 3 Contacts activated in nig...

Page 44: ...e event of over temperature of the device 9 4 7 5 9 Bulk charge phase 14084 14136 no The auxiliary contact is activated if the battery is charging in the bulk phase 9 4 7 5 10 Absorption phase 14085 14137 no The auxiliary contact is activated if the battery is charging in the absorption phase 9 4 7 5 11 Equalization phase 14086 14138 no The auxiliary contact is activated if the battery is charging...

Page 45: ...ording to the state of charge of the battery SOC If the SOC falls below the set level the contact will be activated A time period can be associated with the SOC level to stipulate that the battery must be below the set level a certain time before the contact is activated Three voltage limits with associated delay periods are available for programming The contact is deactivated when the battery s S...

Page 46: ...quipment Displaying the operating synoptic for each part of the equipment Displaying several operating quantities measured or calculated Current Voltage Power etc for each apparatus Updating the software or implementing tailored software Backing up restoring system parameters configuration Loading a parameter file configuration Storing error message history for each device Recording VarioString s ...

Page 47: ...rature A temperature sensor is optionally available to correct the battery voltage and guarantee an optimum charge for whatever battery temperature The correction factor given by the temperature sensor is set by parameter 14035 A single temperature sensor connected to one of the devices is enough in a system containing several VarioString connected to the same battery bank multi system Reference n...

Page 48: ...ey then belong to a system where they are interconnected via the communication bus The full description of this equipment is available on our website www studer innotec com 11 1 XTENDER INVERTER CHARGERS The VarioString is compatible with the entire Xtender range and it allows making PV generator or PV network hybrid systems that are perfectly coherent The communication between the Xtender s and t...

Page 49: ...notebook computer 11 5 COMMUNICATION MODULE XCOM SMS The communication module Xcom SMS makes it possible to access systems with Studer Innotec devices through SMS Short Message Service sent from a mobile phone a web site etc It provides the user with a tool that gives easy access to the system in order to know its current state and to control it remotely reducing the necessity to physically go to ...

Page 50: ...otective earth Class I to which they must be connected T2 Protective earth for the battery One of the battery poles must be earthed The other configurations must meet the recommendations at chap 4 3 8 T3 Protective earth for the solar generator The protective earth for the PV generator and its lightning protection device are connected separately to the main protective earth local equipotential bon...

Page 51: ...ted to the conductive and accessible parts of the building and if possible connected to a standard earth electrode T1 Protective earth for the equipment The equipment is designed to be connected to a protective earth Class I to which they must be connected T2 Protective earth for the battery One of the battery poles must be grounded The other configurations must meet the recommendations at chap 4 ...

Page 52: ...d cadmium mercury hexavalent chrome PBB or PBDE To dispose of this product please use the service for the collection of electrical waste and observe all obligations in force in the place of purchase 15 EU DECLARATION OF CONFORMITY The charge regulator described in this manual has been designed and manufactured in accordance with the following directives and harmonized standards Low Voltage Directi...

Page 53: ... equalization phase has finished correctly The message is not sent when the absorption or floating phases are forced in order to exit the equalization phase 138 Error 138 XT master synchronization lost Message sent if the synchronization with the XT has not been received within 10s 140 140 Synchronized on XT master Message sent after receiving the first frame of synchronization with XT 150 Error 1...

Page 54: ...rce a new cycle Expert 14029 Voltage level 1 to start a new cycle 48 8 Vdc Expert 14030 Time period under voltage level 1 to start a new cycle 30 min Expert 14031 Voltage level 2 to start a new cycle 47 2 Vdc Expert 14032 Time period under voltage level 2 to start a new cycle 2 min Expert 14033 Cycling restricted Yes Expert 14034 Minimal delay between cycles 1 hours Expert 14035 Temperature compen...

Page 55: ...Vdc Expert 14096 Delay 2 AUX 1 10 min Expert 14097 Battery voltage 3 activate AUX 1 No Expert 14098 Battery voltage 3 AUX 1 48 5 Vdc Expert 14099 Delay 3 AUX 1 60 min Expert 14100 Battery voltage to deactivate AUX 1 54 Vdc Expert 14101 Delay to deactivate AUX 1 60 min Expert 14102 Deactivate if battery in floating phase AUX 1 No Expert 14104 Contact activated with the temperature of battery AUX 1 ...

Page 56: ...Expert 14148 Delay 2 AUX 2 10 min Expert 14149 Battery voltage 3 activate AUX 2 No Expert 14150 Battery voltage 3 AUX 2 48 5 Vdc Expert 14151 Delay 3 AUX 2 60 min Expert 14152 Battery voltage to deactivate AUX 2 54 Vdc Expert 14153 Delay to deactivate AUX 2 60 min Expert 14154 Deactivate if battery in floating phase AUX 2 No Expert 14156 Contact activated with the temperature of battery AUX 2 No E...

Page 57: ... algorithm PV LSF Expert 14198 PV voltage fixed 500 Vdc Expert 14199 Ratio of PV open circuit voltage 0 7 Expert 14201 Remote entry active Open Expert 14202 ON OFF command No Expert 14203 Activated by AUX1 state No Expert 14204 Start equalization No Expert 14205 Send a message when remote entry changes state No Expert 14207 Contact activated with fixed time schedule AUX 1 No Expert 14208 Start hou...

Page 58: ...ring VS 70 VarioString VS 120 Maximum solar power recommended STC 4200 W 7000 W Maximum open circuit voltage Voc 600 V Parallel or independent connection 600 V Connection in series 900 V Minimum functional circuit voltage 200 V Parallel or independent connection 200 V Connection in series 400 V Maximum short circuit current 13A Series or independent connection 13A Parallel connection 26A VarioStri...

Page 59: ...y IEC EN 62109 1 2010 EMC electromagnetic compatibility IEC EN 61000 6 3 2011 IEC EN 61000 6 1 2005 VarioString VS 70 VarioString VS 120 Operating ambient temperature range 20 C to 55 C Relative moisture Max 95 without condensation Degree of protection IP54 IP20 Mounting location Indoors pollution degree 2 VarioString VS 70 VarioString VS 120 Polarity reversal of the PV generator Protected Polarit...

Page 60: ...44 14089 44 14090 44 14091 45 14092 45 14093 45 14094 45 14095 45 14096 45 14097 45 14098 45 14099 45 14100 45 14101 45 14102 45 14103 45 14104 45 14105 45 14106 45 14108 45 14109 45 14110 45 14111 45 14112 45 14113 45 14114 45 14115 45 14116 45 14117 45 14118 45 14119 45 14120 45 14121 45 14122 42 14123 43 14124 43 14125 43 14126 43 14127 43 14128 43 14129 44 14130 44 14131 44 14132 44 14133 44 1...

Page 61: ...Studer Innotec SA VarioString User manual V 2 3 61 ...

Page 62: ...Studer Innotec SA VarioString 62 V 2 3 User manual ...

Page 63: ...Studer Innotec SA VarioString User manual V 2 3 63 ...

Page 64: ...Studer Innotec SA Rue des Casernes 57 1950 Sion Switzerland Tel 41 0 27 205 60 80 Fax 41 0 27 205 60 88 info studer innotec com www studer innotec com ...

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