Charge Controller Manual
Contents
1. SILENTWIND Hybrid Charge Controller HYBRID 600 with LCD multi function displa Instruction Manual WWW SILENTWINDGENER SAR SPRECO LDA com 351253572765 er Email i tha twindgen Congratulations you have bought a high quality SPRECO hybrid charge regulator HYBRID 600 Before first using this gadget please carefully read this manual General information The Silentwind Charge Regulator HYBRID 600 is a combined wind and solar charge regulator with an inbuilt micro controller The Silentwind charge controller HYBRID 600 was especially developed for the Silentwind Generator and enables you additionally to install solar panels up to a wattage of 180 Watt peak or to a max current of 10A Consumers with a maximum current of 10 Amps that are connected to the deepcycle output can be automatically switched off or on by a deep cycle protection function All operating parameters can be seen on an LCD display You can adjust the charge regulator with 5 touch keys on the right and left of the LCD display A LED s on top of the controller additionally informs you about the operating status brake active A LED on top of the case below the LCD display additionally informs about the either manually or automatically activated brake function A thermically switched vent provides the correct operating temperature The Silentwind Generator generates 3phase AC voltage In the charge controller AC is transformed to DC2. 12 or 24 voltage is automatically detected after the first installation All types of lead batteries Gel AGM and acid can be charged The suitable maximum charge voltage depending on the type of battery must be adjusted in the Setup The charge controller is approved Please keep in mind that liquid acid batteries can emit dangerous explosive gas If the place where you mount the charge controller is close to these batteries ensure efficient ventilation Gel or AGM batteries are normally maintenance free and do not emit gas if properly charged Advice Always make sure charge controller is mounted in a dry and as cool as possible place Inhaltsverzeichnis 1 wiring diagramm 2 technical data 3 components of the charge controller 3 1 3 2 3 3 3 4 frontside backside LCD display LED indicator 4 mounting the charge controller 4 1 4 2 SS ES o 9 7 9 8 9 9 mounting by holding brackets mouting in a slurry wall trench Cable cross section installation and Connection of the charge controller connecting solar panels programming charge controller programming instruction 9 1 9 2 9 3 9 4 9 5 9 6 operating keys battery voltage and charge current charge cut off voltage charge amount in ampere hours Ah charge amount in kilowatt hours kWh current charging power consumer settings brake adjustments generator voltage 10 troubleshooting oO A A GT N
3. N nN Oo oO ff A Sa A a 2 22 2 NO oO FP BPW oo od NND NY NY O m BEGY Eu we 2 Technical data hybrid charge controller type Battery system voltage automatically detected Max power input of the wind generator Max current input of the wind generator Max power input of the solarpanel Max current input of the solarpanel Max open circuit voltage input of the solarpanel Max total charge current Max switch off current at LOAD output Load Max voltage adjustable for the battery types Dimensions LxWxH in mm Weight Suitable for Warranty Thermically switched vent Cable connection Integrated electronic brake Integrated manual brake switch LCD display of all relevant working data LED shows the operating status LED for brake function Charging cantreder 190 x 120 x 65 1 15 kg acid gel and AGM 24 months LED occurs brake activated SILENTWIND 3 Components of the charge controller 3 1 Frontside On the front of the charge controller there are screw terminals to connect the battery There are also screw terminals for the automatically switched load output user output as well as the brake switch to activate manually the brake function Please note that the brake switch in position I means that the brake is activated switched on manually but it does not mean that the wind generator is switched on The brake switch does not totally stop the blade
4. programme the requested switch off current at the step Break On paragraph 9 8 We also recommend to make use of the additional adjustments according to your individual requirements If the point of maximum voltage is reached the Silentwind Generator will stop for 20 minutes The break mode of the charge regulator generates internal rising temperatures that are thermically detected Therefore the break time of the Silentwind Generator will be increased in high wind speeds until the internal temperature is reduced by the automatically switched vent For this reason the charge controller should be installed on a place as cool as possible Never install the controller at direct solar radiation or sunlight A special feature of this charge controller is that you can programme the break function If the maximum possible voltage according to the type of battery is reached the charge controller will switch of the Silentwind Generator Additionally the maximum charge current can be adjusted see chapter settings page 12 This means that the Silentwind Generator can also be operated with a larger battery capacity If a large battery capacity is discharged a higher charge current will flow in high wind speeds As you can set the maximum charge current you can prevent overheating of the charge controller As described in step Break On you can reduce the max charge current according to the requirements Advice If the capacity o
5. rotation The blades will still turn slowly If the brake is manually or electronically activated the LED brake will lit up The brake switch should be manually activated in case of storm maintenance or if you want to work close by the Silentwind Generator For automatic brake mode please switch position 0 RELEASE Front view manual brake switch user output battery 3 2 Backside On the backside of the charge controller there are screw terminals to connect the wind generator and the solar panels Rear view PV input wind generator input 3 3 LCD Display On the top of the charge controller there is an LCD display that is necessary to adjust the charge controller and that shows you all operating data during the working process 3 4 LED indication The LED brake shows you that the charge controller has activated the electronic brake function or that the manual brake switch is switched on 4 Mounting the charge controller The charge controller can be mounted in various cways We suggest these possibilities 4 1 Mounting with holding plates brackets picture 1 Mount the charge controller with the enclosed holding plates as shown in picture 1 Use suitable screws depending on the mounting material Screws are not included in delivery 4 2 Mounting in a slurry wall trench picture 2 As you can see from picture 2 there are 4 mounting holes on the back of the charge co
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7. e In the display mode shown above charge off you can set the max possible voltage of your battery with the buttons and Please note the instructions of the manufacturer of the batteries The maximum possible voltage is dependent on the system voltage 12 24V and the type of battery acid Gel or AGM 9 4 Charge amount in Ampere hours Ah er nr par tens en AS Charge shows how many ampere hours Ah have been charged into your battery This is updated every 10 seconds 9 5 Charge amount in Kilowatt hours kWh RE at Be Charge shows you the amount of kWh have been loaded into the battery This parameter is updated every 10 seconds nw 7 ae As a _ wg ef Fe A Ue Tri Fa u i Zas 2 u thr oP a werd T oe ie rar ar u gt d 9 6 Current charging power This shows you the wattage flowing at the moment incl Solar power 13 9 7 Consumer settings pees Auf Py Fi w ey os A wee less u Hie Soy h d e fk BIEN pena I A A i p rk anA Bi g l Lad d si a j f A FP a fe His 7 u J 4 I You can also connect a consumer to the screw terminals of the load output and define when the consumer should be switched on and off The consumer is called user in the picture above This shows you how many amphours the user has taken With the button and you can define the voltage when the charge regulator
8. e cable sockets It is most important that you first connect the charge controller to the battery with the right polarity Attention On the output of the charge controller there must not be an additional brake switch In case there is such a brake switch due to the previous installation of a wind generator this must be removed Please connect the enclosed fuse 50Amp close to the battery in the positive wire The fuse is only included in delivery if you buy a wind generator not only a charge controller Attention The confusion of Plus and Minus will definitely destroy your charge controller In that case warranty is gone After the connection of the battery you can connect the load output the Silentwind Generator and if required a solarpanel On the 3 phase output wires of the Silentwind you need not to pay attention to polarity If you want to connect 24 volt batteries to the charge controller make sure that the voltage of the batteries is above 20 Volt Otherwise the charge controller will detect a 12 volt battery system If you install this system after having used another windgenerator with a stop switch make sure that this switch is deactivated or removed If there is sufficient windspeed when connecting the Silentwind Generator this will immediately generate electric power at the end of the 3 AC wires without being connected to the charger Therefore we recommend to block the Silentwind Generator blades with a rope b
9. efore connecting the wires to the charger The 3 AC output wires must be connected to the 3 screw terminals on the back of the charge regulator see paragraph 3 2 In a 3 phase AC system the connection order polarity does not matter 9 In case you want to connect additional solarpower max 180Wp or 10A to the charge controller this should be done by using the PV screw terminals Please make always sure that you do not confuse polarity You can find the connection diagram in paragraph 7 7 Connecting solar panels The charge controller Hybrid 600 is a hybrid controller both for wind and solar energy Solar panels with a max power of 180 Wp 10 A can be connected See technical details page 4 Connect the solar panels according to the following sketch 12 volt system Modul 1 Modul 1 Modul 2 Ja jo U0D abieys open circuit voltage 18V 22V 5 open circuit voltage charge controller 24 volt system Modul 1 Modul 1 Modul 2 open circuit voltage 36V 44V gt 36V 44V _ _ charge controller charge controller open circuit voltage 10 8 Programming charge controller Before first using the charge controller it must be adjusted to the type of battery acid gel AGM you want to use see paragraph 9 At first you have to programme the max possible voltage according to the instructions of the battery manufacturer in step Charge Off paragraph 9 3 secondly you have to
10. f the batteries is less than 150 Ah or old batteries have lost their original capacity the point of max voltage can be reached very fast although the battery is not fully charged yet In this case it can be useful to connect an electric consumer to the Load output as this will reduce the voltage and thus prevent that the break mode is activated too early 11 9 Programming instruction 9 1 Operating keys The charge regulator has 5 operating keys on the top With the menu key you move through the menu With the OK key you move back with the and keys you can change the different parameters With the RESET key the inbuilt micro processor is restarted your settings will not be resetted 9 2 Battery voltage and charge current The system voltage is automatically detected as soon as the charge regulator is connected to the battery Please only connect batteries that are sufficiently charged If the battery of a 24V system is discharged it is possible that the charge controller detects a 12 V system After the first connection the display shows the following data The display shows Hybrid NL 12V system voltage Hybrid NH 24V system voltage a f AD e Y A N Ren 4 by gt We A y Pg D q v N N N E i SR t a 4 AN In the display mode you can see above the battery voltage and the charge current The total current wind and solar is shown 12 9 3 Charge cut off voltag
11. k the installation chain starting at the 3 wires of the Silentwind Generator connected to the charge controller In case the Silentwind Generator does now start without connection to the charge controller the failure is between charge regulator and battery BE CAREFULL don t touch the end of the cables because of the electric power that occurs at these ends If the Silentwind Generator continues to turn slowly the failure is between charge controller and Silentwind Generator Mind the recommended cross section of the wire as well as the recommended minimum capacity of the battery that you want to charge If the Silentwind Generator generates too little power e The wind speed is too low see the performance diagrams shown in the manual of the Silentwind The wind speed measured on top of the mast is higher than at the position of the wind generator e Turbulences by obstacles in the wind direction or the location is unsuitable mast to short e The wire cross section is not in line with the lenght of the wires installed see page 3 e The battery capacity is below 100Ah so that the maximum possible voltage is generated too fast e The battery is too old and has lost capacity so that the maximum power voltage is achieved too fast Enjoy collecting regenerative power You contribute protecting the environment and saving your money Your Spreco Team edition October 2011 17 www SILENTWINDGENERAJER SPRECO LDA Phone 35125
12. ntroller Use filister head screws with appropriate suitable diameter and screw them into the mounting surface according to the measurements shown in the picture above Don t screw them completely into the mounting surface Place the mounting holes over the screws and slide the charge controller into the 4 slurry wall trenches Screws are not included in delivery 5 Cable cross section As you can see from the wiring diagram in paragraph 1 a 3 pole cable with suitable cross section must be wired from the Silentwind Generator to the charge controller The charge power gets from the charge controller to the batteries through two wires on the AC entrance through three wires Therefore the cross section of the two wires on the DC output should be larger we recommend a minimum cross section of 10mm See below table to find the correct cable cross section System voltage 12 Volt Distance from 10 19 20 29 30 44 45 69 70 110 windgenerator to the charge controller in m Cable cross section mm AWG en oh wa alu at nie contr to the battery inm oe ee oe on AWG 8 6 4 2 System voltage 24 Volt Distance from 10 19 20 29 30 44 45 69 70 110 windgenerator to the charge controller inm EEE AWG 14 12 10 en Ws sty aa ota ate ww contr to the battery inm i LAENEN AWG 8 6 4 2 6 Installation and connection of the charge controller The charge controller should be mounted close to the battery in a ventila
13. ooled down Therefore this time should not be programmed below 50sec 9 9 Generator voltage Reference voltage only relevant for service purposes 15 If the charge controller is correctly connected the manual break switch on the front of the charge controller can be switched in position 0 The Silentwind Generator will then start to turn faster until the charging process starts The charge controller now starts operating and monitors all special settings that you have programmed according to the type of battery and the instructions of the battery manufacturer see examples for settings Saftey advice Please never disconnect the battery wires while the Silentwind Generator is charging This will immediately destroy the charge controller If you want to measure the current flowing an amp meter must be installed in the positive battery wire Mind the polarity of the amp meter The flowing current can be seen at the LCD display Notices 16 10 Troubleshooting The blades of your Silentwind Generator are turning too slowly e The manual stop switch of the charge controller is in position l BRAKE e Connecting the wires possibly caused a short circuit between the wires e The wind speed is too low e The fuse connected to the battery is gone e Your Silentwind Generator or the charge regulator has an internal problem Please contact your dealer In order to find the mistake you have to chec
14. should switch off the consumer Please note that this must not be higher than 10 Amp User on defines the voltage when the consumer can be switched on again As the voltage of the battery increases when switching off the consumer this will steadily switch on and off the load output if this value is not high enough This function can also be used with smaller batteries So that the charge voltage is not detected too fast you can connect a consumer additionally This avoids that the brake will be activated too early This setting shows how much amps the consumer that is connected to the load output is using 14 9 8 Brake adjustment With you can set the current when you want to stop the Silentwind Generator This prevents overheating especially with big battery banks and high loading currents This function can also be used to reduce the RPM of the Silentwind Generator You can calculate the max charge current value as follows The max power of the Silentwind Generator 400 Watts divided by the max cut off voltage e g 14 4 Volt ata AGM battery The max possible charge current in this example is 400VA 14 4V 2 Amp Breaktime With this setting you can programme the period of time that you want to stop the Silentwind The longer you programme the time the longer the first break intervals will take This procedure will heat up the inbuilt brake resistores resulting in a permanent brake mode until the vent has c
15. ted and cool location which enables you to read the information shown on the LCD display and to operate the manual brake switch easily Safety advice Especially acid batteries can emit gas when charging Therefore the charge controller must not be installed close to those batteries In case of high concentration of dangerous gas there is a risk of explosion Please note the safety regulations advice of the battery producer If the acid batteries are equipped with ventilation pipes to the exterior or if the storage room of the batteries is otherwise ventilated the charge controller can be installed close to the batteries Please find a sketch of the wiring diagram in the paragraph 1 of this manual Make sure that you fix the wires properly to prevent them from getting loose due to vibrations Fix the plastic screw nuts sufficiently to ensure electric contact We recommend the use of the enclosed wire kits 3 x HO7V K 4mm red input of 3 phases of the wind generator 1 x HO7V K 6mm red output to battery 1 x HO7V K 6mm black output to battery Connect the free end of the connecting wire with your wires coming from the wind generator and the battery with suitable insulating screw joints In case you do not use the connecting wires we recommend the use of crimp type cable sockets to fix your wires directly to the charge controller After having fixed the crimp type cable sockets with the bared wires these can be fixed to th
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