User manual

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This document is the property of WESTERN CO. Srl. All rights are reserved.
Reproduction and use of information contained within this document is forbidden
without the written consent of WESTERN CO. Srl.
2
PHOTOVOLTAIC BATTERY CHARGE REGULATOR
WR 10/20/30
Address:
WESTERN CO. Srl
Via Pasubio 1
63074 San Benedetto del Tronto (AP) - Italy
tel [phone] fax [phone]
e-mail: [e-mail]
web: www.western.it
Features
WR10/20/30 is a charge regulator from PV modules for electric batteries. It can be
used either in small or in big systems for homes, industries or telecommunication
systems. It controls the PV module current with PWM and the battery discharge by
disconnecting the load in case of deep discharge of the battery. The load can be
activated according to different programs which can be set by the user: load
always ON, load ON only during the day, load ON only during night, load ON only
during night and configurable for a number of hours included from 1 to 16. The
different programs of load management make WR10/20/30 the complete solution
in many PV applications; for example: to power supply video cameras that have to
work only during day, to power supply flashing systems or road signalling systems
that have to work only during night, to power supply lighting systems that have to
work for a specified number of hours per night. WR10/20/30 notes the day/night
status according to the PV module voltage; therefore it is not necessary to connect
further sensors to the regulator.
There are 3 versions: WR10, WR20 and WR30 respectively for PV module
currents of max 10A (WR10), 20A (WR20) and 30A (WR30). In this manual when
we write WR10/20/30 we refere to all versions WR10, WR20 and WR30.
The charge voltage is compensated in temperature so to charge the batteries even
with extreme temperature conditions (from -10 to 60 °C) without compromising the
useful life. You can set charge programs either for GEL/AGM sealed batteries
(SEAL) or for flooded lead acid batteries (FLOOD). In fig. 5 there are the charge
voltages according to the temperature for the two programs that can be set. It is
compulsory to verify in the technical manual of your battery if the charging voltage
is appropriate to the battery.
The battery can have a nominal voltage either 12V or 24V; at its first starting
WR10/20/30 measures the battery voltage and, if it is > of 18V, it sets the charge
program for 24V battery, while if it is < of 18V it sets the charge program for 12V
battery.
The internal circuit is completely made with solid state components (MOSFET);
therefore in comparison with similar products having electro-mechanical
components, we guarantee a greater reliability in time.
The circuit has got the following protections:
Polarity inversion of battery: if you invert the battery terminals, WR10/20/30 does
not power on, it does not power the load and it signals a mistake to the operator.
Revers current on PV modules: during night, when PV module does not produce
current, WR10/20/30 charge regulator has an internal reverse current diode that
avoids the battery discharge towards the PV module.
Low-battery: When battery voltage drops below Vlb threshold (selectable)
WR10/20/30 charge regulator disconnects the load to protect the battery from
deep discharge.
Short-circuit on the load: If the current on load
overcomes the nominal value equal to 10,0 A for
WR10, 20,0A for WR20 and 30,0A for WR30 for more
than 0,5 seconds, the regulator disconnects the load.
Over-temperature: when the internal temperature
overcomes 80°C, both PV module and load are
disconnected so to avoid that excessive over-heating
provokes the breakage of the circuit.
Overload on PV module: if current from PV module
overcomes Ipan max the WR10/20/30 stops the
charge current to protect its internal circuit.
Installation
For a right heat dissipation you have to install
WR10/20/30 so not to obstruct the movement of air below the regulator, especially
when it works at high temperatures.
WR10/20/30 must be fixed either on a vertical wall or on an horizontal not-
flammable surface and protected against humidity; therefore it cannot be installed
in outdoor applications. For outdoor applications WR10/20/30 has to be housed in
a proper box that has to be protected against water and humidity, even better if the
box is metallic so to dissipate the produced heat.
The regulator has to be placed as close as possible to the battery so to make the
cables as short as possible. The cables’ section has to be chosen so to avoid that,
during the system working, they can go in overheating. For PV modules with
currents > of 10A
we advise the use
of cables section of
10mm
2
; for PV
modules from 5A
to 10A we advise
the use of cables
section of 6mm
2
and for PV
modules with
current < to 5A we
advise the use of
cables section of
4mm
2
.
In fig. 2 there is the
scheme of electric
connection of
WR10/20/30. The
connection of the
case to the ground
is not compulsory,
but it is advised for
a more effective protection
against lightning.
If you have to connect a battery
terminal on the ground you can do
it as in fig 3a; it is possible to
connect together on the ground
the connectors: +PAN, +BATT
and +LOAD as in fig 3b; on the
contrary, it is not possible to
connect the ground as in fig 3c.
The PV module that has to be
connected with WR10/20/30
regulator, has to be chosen by
respecting the following criteria:
-The short-circuit current (Isc) of
PV module must not overcome
the nominal current of 10A for
WR10, 20A for WR20 and 30A for
WR30.
-The open-circuit voltage (Voc) of
the PV module has to be chosen
according to the voltage of the
battery that has to be charged.
When a battery is in charge its
voltage changes from 11.0V to
14.4V for systems @ 12V and
from 22.0V to 28.8V for battery @
24V. The chosen PV module must
have its maximum power voltage
(Vmp) equal to the maximum
battery voltage (fig. 4b and 4e). If
you choose a module with a Vmp
much greater than the maximum
battery voltage (fig. 4a and 4d)
you risk not to exploit the whole
PV module’s charge. Otherwise if
the chosen Vmp is too small in
comparison with the interval of
variation of the battery voltage (fig. 4c and 4f) you risk that the battery will not be
able to charge at its maximum voltage.
Ipan
Vpan
Vbatt
11V
Vbatt
14.5V
Vpan Vpan
Vbatt
11V
Vbatt
14.5V
Vbatt
11V
Vbatt
14.5V
Ipan Ipan
T25°C
T35°C
T55°C
T25°C
T35°C
T55°C
T25°C
T35°C
T55°C
Ipan
Vpan
Vbatt
22V
Vbatt
28.8V
Vpan Vpan
Vbatt
22V
Vbatt
28.8V
Vbatt
22V
Vbatt
28.8V
Ipan Ipan
T25°C
T35°C
T55°C
T25°C
T35°C
T55°C
T25°C
T35°C
T55°C
fig. 4a
fig. 4b
fig. 4c
fig. 4d
fig. 4e fig. 4f
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p
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m
p
V
m
p
V
m
p
V
m
p
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m
p
OK
OK
NO
NO
NO
NO
System working
Day/night status
It is displayed only in the configuration screens Low battery protection is active
Load Power on
It indicates whic h charge
program is actually set
It displays internal measures
Volt age l evel i n the ba tt ery
Indication of current
absorption on the load
Ind i ca ti on of cu r re nt
ab s or
p
ti on from P V
Main page.
It shows the battery voltage, the day/night status taken from the PV
module. If the load icon is ON it means that the load is power supplied and
you can see the charge program currently selected.
It shows the current of PV module. We remember that the current delivered
by the PV module depends on its state of sun irradiation and on the battery
state of charge. In condition of charged battery (Vbatt>14,4V @12V or
Vbatt>28,8V @24V) even with a good sun irradiation of the module we
have low charge currents since the regulator limits such a current to avoid
a battery overcharge.
It shows the power in watt actually delivered by the PV module.
It displays the counter of energy that is delivered from the module in KWh.
It is possible to reset such measure by pushing at the same time the push-
buttons for 2 seconds
It displays the temperature of battery that is measured by the internal
sensor to WR10/20/30.
It displays the current actually delivered to the load; even if in this screen
there is the load icon ON, this does not mean that the load is not effectively
power supplied. In fact the load is controlled according to the program of
load management which is actually set.
It shows the power actually delivered to the load in watt.
Here you can see the counter of energy in KWh that have been consumed
by the load. It is possible to reset this counter by pressing at the same time
the push-buttons for 2 seconds.
When you press the left button you return to the main page.
System configuration
You can access to the configuration pages of W R10/20/30 by pressing for at least
2 seconds the push-buttons
.
Configuration page of charge program
It sets the charge program for the battery.
We advise to set the SEAL program for
PB sealed AGM / GEL batteries, while we
advise to set the FLOOD program for the
charge of flooded lead acid batteries.
change of page
Configuration page of Low Battery voltage
It sets the intervention volta
g
e of Low Batter
y
protection
(load disconnection in case of discharged battery). By
pressing the push-button you modify the setting
from 10.8V to 12.2V for systems @ 12V and from
21.6V to 24.4V for systems @ 24V.
change of page
Configuration page of load management program
.
Load always ON
either during day
or during
night.
Load ON
only during
day
Load ON only
during night
.
Load ON
during night for
1 hour .
Load ON
during night
for 16 hours
change of page
It displays the software version and
ampere size of regulator (10A / 20A /
30A).
Press left button to go back to the configuration page of charge program.
Once you have modified the settings of WR10/20/30 these become operative only
after having left the configuration pages by pressing for at least 2 seconds the
push-buttons
Error code
When in WR10/20/30 an internal protection occurs, it is displayed the error code
(see table below).
Error code table
You have connected the battery with inverted polarities. Control the wiring.
It occurs when internal temperature of WR10/20/30 rises above 80°C. In this case
battery charge is disabled. You comes out automatically from this protection when
the temperature drops below the threshold of 50 ° C (internal temperature is not
displayed in the LCD). If this protection occurs often we suggest to install the
WR10/20/30 in a cooler place.
It occurred the overload protection. The load current has exceeded the maximum
limit allowed for the WR10/20/30 (Iload in table electric feature) and the regulator
has disconnected the load to prevent internal breaking. If you see this message you
should check if the current absorbed by the load is lesser than the permitted limit.
After 1 minute the WR10/20/30 power supplies back the load.
The PV current has exceeded the maximum allowable current (Iload in table
electric feature) and the regulator has disconnected the PV to prevent internal
breaking. After about 1 minute WR10/20/30 re-activates the charge automatically.
You have this protection when you connect to the regulator a PV module with too
high current (Isc of the PV module exceeds Ipan on the table of electrical features);
therefore you must choose a different PV module.
Charge voltage To temperature for 12V battery
13,50
14,00
14,50
15,00
15,50
16,00
-10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
Temperature °C
Charge voltage Volt
SEAL FLOOD
Charge voltage To temperature for 24V battery
27,00
27,50
28,00
28,50
29,00
29,50
30,00
30,50
31,00
31,50
32,00
-10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
Temperature °C
Charge voltage Volt
SEAL FLOOD
fig. 5
ELECTRIC FEATURES
WR10 WR20 WR30
Min Typ Max Min Typ Ma
x
Min Typ M ax
Battery voltage
Vbatt [V] 10 - 35 10 35 10 35
Module voltage
Vpan [V] - - 55 - - 55 - - 55
Module current
Ipan [A] - - 10 - - 20 - - 30
Charge voltage
@ 25°C prog.
SEAL
Iload [A] - - 10 - - 20 - - 30
Charge voltage
@ 25°C prog.
FLOOD
Vch 14.4V @12V
28.8V @24V
Threshold of low
battery protection
Vch 14.8V @12V
29.6V @24V
Threshold - exit
low battery
protection
Vlb Settable from 10.8V to 12.2V @12V
Settable from 21.6V to 24.4V @24V
Self-consumption
VexLb Vch – 1V @ 12V
Vch – 2V @ 24V
Working
temperature
Isleep [mA] 8,0 8,0 8,0
Dissipated power
Tamb °C -10 - 60 -10 - 60 -10 . 60
Conductors
section
Pdiss 6.8W @10A 8.0W @20A 16.0W @30A
Box IP degree
mm
2
1 - 10 1 - 10 1 - 10
Battery voltage
IP20
Mechanical dimensions
Fig 2