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PHOTOVOLTAIC BATTERY CHARGE REGULATOR

WR 10/20/30

Address:

WESTERN CO. Srl

Via Pasubio 1

63074 San Benedetto del Tronto (AP) - Italy

tel +39 0735 751248 fax +39 0735 751254

e-mail: info@western.it

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 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, voltage drop is less than 3% of system nominal voltage.

For PV modules with currents > of 10A we advise the use of cables section of

10mm

; for PV modules from 5A to 10A we advise the use of cables section of

6mm

and for PV modules with current < to 5A we advise the use of cables section

of 4mm

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

T25°C

T35°C

T55°C

T25°C

T35°C

T55°C

T25°C

T35°C

T55°C

Vpan

Vbatt

22V

Vbatt

28.8V

Vpan Vpan

Vbatt

22V

Vbatt

28.8V

Vbatt

22V

Vbatt

28.8V

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

Vmp

Ipan

System working

Day/night status

It is displayed only in the configuration screens Low battery protection is ac tive

Load Power on

It indicates whic h charge

program is actually set

It displays internal measures

Voltage level in the battery

Indication of current

abs orption on the load

Indication of current

absorption from PV

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 WR10/20/30 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 voltage of Low Battery 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

It sets the threshold for exit from low battery protection. By pressing the push-

button you modify the setting from 12.4V to 13.8V for 12V systems, and from

24.8V to 27.6V for 24V systems.

This setting is available only for firmware version ≥2.1

cambio pagina

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

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

Temperature °C

Charge voltage Volt

SEAL

FLOOD

fig. 5

ELECTRIC FEATURES

WR10

WR20

WR30

Min

Tip

Max

Min

Tip

Max

Min

Tip

Max

Battery voltage

Vbatt [V]

Module voltage

Vpan [V]

Module current

Ipan [

Load current

Iload [A]

Charge voltage @

25°C SEAL

Vch

14.4V @12V

(default)

28.8V @24V (default)

Charge voltage @

25°C FLOOD

Vch

14.8V @12V

29.6V @24V

Threshold of low

battery protection

Vlb

impostabile d

a 10.8V a 12.2V @12V

(11.6V default)

impostabile da 21.6V a 24.4V @24V (23.2V default)

Threshold for exit

from low battery

protection

VexLb

impostabile da 12.4V a 13.8V @12V*

(13.8V default)

impostabile da 24.8V a 27.6V @24V* (27.6V default)

Self

consump

tion

Isleep [mA]

8,0

Working temperature

Tamb °C

Power dissipation

Pdiss

6.8W @10A

8.0W @20A

16.0W @30A

Wiring section

IP box degree

IP20

*This setting is available only for firmware version ≥2.1

Mechanical dimensions

Warranty

Western Co. Srl guarantees the good quality and good manufacture of its own Products obliging itself, during

the warranty period of 5 (five) years. Warranty condictions can be read at www.western.it.