Steca Solarix PLI Inverter Hybrid Charger Instruction Manual

Steca Solarix PLI Inverter Hybrid Charger

Product Information

• Specifications
  • Model: Solarix PLI 5000-48, Solarix PLI 2400-24, Solarix PLI 1000-12
  • Functions: Off-grid inverter, MPPT solar charger, AC transfer, battery charger
  • Nominal Voltage: 48Vdc (PLI 5000-48), 24Vdc (PLI 2400-24), 12Vdc (PLI 1000-12)
  • The Steca Solarix PLI is a multi-function inverter/charger that combines various functions to provide an uninterruptible power supply.
  • It includes an off-grid inverter, MPPT solar charger, AC transfer capability, and a battery charger.
  • The unit is compact and features a comprehensive LC display for easy configuration and data readout.
• Features
  • User-configurable button configuration
  • Readout of relevant data on the LC display
  • Compatible with Solarix PLI accessory (one kit required per inverter)
• Basic System Architecture
  • The unit can be used in various system configurations.
  • The basic application includes a battery, generator or utility as the power source, and PV modules for solar charging.
  • If both a generator and utility are used in a single system, an external source selector is required.

Product Usage Instructions

• Safety Instructions
  • Before using the Steca Solarix PLI, it is important to read and understand the following safety instructions:
  • This document is part of the product.
  • Only qualified service professionals should perform the installation work described in this manual.
  • Read all instructions and cautionary markings on the unit, batteries, and this manual before using the unit.
  • Use only rechargeable deep-cycle lead-acid batteries with liquid electrolyte, AGM, or gel. Do not use other types of batteries unless approved by KATEK Memmingen GmbH.
  • The unit should only be used with batteries that have a nominal voltage of 48Vdc (PLI 5000-48), 24Vdc (PLI 2400-24), or 12Vdc (PLI 1000-12).
  • Do not disassemble the unit as it may cause damage and personal injury.
  • Take caution when working with metal tools near batteries to avoid potential risks.
• Installation
  • Follow these steps to install the Steca Solarix PLI:
  • Select a suitable location for the unit that is well-ventilated and free from excessive heat or moisture.
  • Ensure that the unit is securely mounted or fixed in place.
  • Connect the battery to the unit following the polarity markings.
  • Connect the PV modules to the unit using appropriate cables and connectors.
  • If using a generator or utility as a power source, connect it to the unit using the AC input terminals.
  • Verify all connections are secure and properly tightened.
• Operation
  • To operate the Steca Solarix PLI, follow these steps:
  • Turn on the unit by pressing the power button.
  • Use the buttons on the LC display to configure the desired settings.
  • Monitor the relevant data displayed on the LC display to ensure proper operation.
  • Refer to the user manual for detailed information on configuring specific functions and settings.
• Troubleshooting
  • If you encounter any issues with the Steca Solarix PLI, refer to the troubleshooting section of the user manual for possible solutions. If the issue persists, contact a qualified service professional for assistance.
• FAQ
  • Q: Can I use non-rechargeable batteries with the Steca Solarix PLI?
  • A: No, the unit is only compatible with rechargeable deep-cycle lead-acid batteries with liquid electrolyte, AGM, or gel.
  • Q: What is the maximum voltage supported by the Solarix PLI 2400-24 model?
  • A: The Solarix PLI 2400-24 supports a maximum nominal voltage of 24Vdc.

About this manual

Purpose

• This manual describes the assembly, installation, operation and troubleshooting of this unit (also referred to as “inverter” throughout this manual or “PLI 5000-48” for the Solarix PLI 5000-48, “PLI 2400-24” for the Solarix PLI 2400-24, or “PLI 1000-12” for the Solarix PLI 1000-12 models).
• Please read this manual carefully before installation and operation. Keep this manual for future reference.

Scope

• This manual provides safety and installation guidelines as well as information on wiring and operation.

Keywords and symbols

• These keywords are used in this manual with the following meanings:

equipment

This symbol indicates a warning or danger, pay particular attention to these sections.

General safety instructions

WARNING: This chapter contains important safety and operating instructions. Read and keep this manual for future reference.

1. This document is part of the product.

2. CAUTION Only qualified service professionals may perform the installation work described in this manual.

3. Before using the unit, read all instructions and cautionary markings on the unit, the batteries and all appropriate sections of this manual.

4. CAUTION To reduce risk of injury, charge only rechargeable deep-cycle lead-acid batteries with liquid electrolyte, AGM or gel. Other types of batteries may burst, causing personal injury and damage, if they are not approved by KATEK Memmingen GmbH. Use only batteries with 48, 24 or 12 Vdc nominal voltage with the PLI 5000-48, PLI 2400-24 and PLI 1000-12, respectively.

5. Do not disassemble the unit, doing so may cause damage to the unit, personal injury and leads to a total loss of warranty. Contact your dealer when service or repair is required. Incorrect re-assembly may result in a risk of electric shock or fire.

6. To reduce risk of electric shock, disconnect all wirings before attempting any maintenance or cleaning. Turning off the unit will not reduce this risk.

7. CAUTION Never charge a damaged or frozen battery.

8. CAUTION For optimum operation of this unit, please follow the required specification to select appropriate cable sizes. Failure to do so may cause damage.

9. Be very cautious when working with metal tools on or around batteries. A potential risk exists in short-circuiting batteries or other electrical parts, potentially causing an explosion or fire. Use only insulated tools.

10. Please strictly follow installation procedure when connecting or disconnecting AC or DC terminals. Please refer to the ”Installation” section of this manual for the details.

11. WARNING Ensure that all cables, particularly the AC input, AC output, photovoltaic (PV) and battery cables are seated properly in their contacts and tightened correctly. No cable insulation may protrude into the corresponding cable terminals. Any materials other than the cable / cable lug /ring terminal inserted into the terminals could cause excessive heating, damage and / or fire.

12. Make sure to use a battery fuse as close as possible to the battery terminal with a rating of 200 A DC for the PLI 1000-12 or 250 A DC for the other units as over-current protection for the battery and battery cables. The fuse must be able to reliably protect the battery cables from short-circuit or overload.

13. WARNING This inverter is required to be connected to a permanent grounded wiring system via the appropriate terminals. Failure to do so may cause serious personal injury. Be sure to comply with local requirements and regulations when installing this inverter.

14. Never allow the AC output and DC input to be short-circuited. Do NOT connect to the AC mains when the DC input short circuits.

15. If one of the following components is damaged immediately take the device out of operation and disconnect it from the AC mains, battery and PV modules: the device itself (not functioning, visible damage, smoke, penetration of liquid etc.), connected cables or solar modules.
    Do not switch the system on again before the device has been repaired by a dealer or the manufacturer, damaged cables or solar modules have been repaired by a technical specialist.

16. Any use of this product aside from its intended purpose as described in this manual could lead to damage and/or serious personal injury. Opening any part of the device apart from the bottom cover as described in this manual will void the warranty and can lead to damage and/or serious personal injury.

17. Only for indoor use, pollution degree 2. Not for use in workshops or other high-dust environments without counter-measures.

18. CAUTION Heavy device. Take care when lifting the device to avoid injury.

Introduction

• This is a multi-function inverter/charger, combining functions of off-grid inverter, MPPT solar charger, AC transfer from an AC source to AC loads, and a battery charger from an AC source to offer an uninterruptible power supply with a compact size.
• Its comprehensive LC-display offers user-configurable and easily-accessible button configuration as well as a readout of relevant data.

Features

• Pure sine wave inverter
• Built-in MPPT solar charge controller
• Configurable AC input voltage range limit for home appliances or personal computers
• Configurable battery charging current based on applications via LCD setting
• Configurable AC / solar charger priority via LCD setting
• Compatible with AC voltage from the grid or generator power
• Uninterruptible power supply in case of grid black-out
• Bipolar disconnection from the AC input in inverter mode, grid injection is not technically possible
• Overload, over-temperature and short-circuit protection
• Smart multi-stage battery charger with optional equalisation for optimised battery performance
• Up to nine inverters can be connected in parallel or as a 3-phase system with the optional Parallel Kit for Solarix PLI accessory (only Solarix PLI 5000-48 or Solarix PLI 2400-24, one kit required per inverter)

Basic System Architecture

• The following illustration shows the basic application for this unit. It also includes the following devices to have a complete running system: battery, generator or utility (if both are used in a single system an external source-selector is required as shown in Fig. 1), and / or PV modules.
• Consult with your system integrator for other possible system architectures depending on your requirements.

Product Overview

1. LCD
2. Status indicator for line/inverter mode
3. Charging indicator
4. Fault indicator
5. Function buttons (ESC, UP, DOWN, ENTER)
6. Circuit breaker
7. AC input
8. AC output
9. RS-232 communication port
10. USB communication port (not available for PLI 1000-12)
11. Signal contact
12. PV input
13. Battery connection (positive)
14. Battery connection (negative)
15. Power on/off switch for the inverter unit (the charge controller will charge the battery if solar power and voltage is available and sufficient, regardless of the position of this power switch).

Installation

Unpacking and Inspection
Before installation, please inspect the unit. Be sure that nothing inside the package is damaged. Included items:

• The inverter unit
• Installation and operating instructions
• RS-232 communication cable
• USB cable
• Ring terminal (3x)

Preparation
Before connecting all wirings, please take off bottom cover by removing the two screws shown in Fig. 3.

Mounting the Unit

WARNING: Suitable for mounting on concrete or other non-combustible surface only. This is a class-A product. In a domestic environment, this product may cause radio interference in which case the user may be required to take adequate measures.

Consider the following points before selecting where to install:

• Do not mount the inverter directly above batteries, as corrosive battery gases can damage the inverter
• Mount on a solid, non-flammable surface
• Install this inverter at eye level to allow the LCD to be read at all times
• The ambient temperature should be between 0 °C and 55 °C. The place of installation shall have natural ventilation, low dust and humidity is less than 90%.
• The recommended installation position is adhered to the wall vertically. Please beware that due to fan noise it is recommended to install the unit in a closed room.
• Be sure to keep other objects and surfaces at least as far from the installed inverter as shown to the right in Figure 4 to guarantee sufficient heat dissipation and to have enough space for removing wires 
• Fix the unit to the wall by using three M5 screws (not included) in the screw holes pictured below in Figure 5. Be sure to take precautions such as wall plugs, ensuring that the inverter’s weight can be safely held by the wall and screws.

Residual current circuit breaker (RCD)

Due to its design, the inverter cannot cause a DC fault current. Therefore, the installation of a Residual Current Device (RCD) is not necessary. If local installation regulations or the power supply company require the installation of an external residual current device (RCD) in the AC connection line, a type A residual current device (RCD) is sufficient according to IEC 62109-1. The tripping current should be rated at least 100 mA or higher. If several inverters are installed in a system, a corresponding earth-leakage circuit breaker (RCD) must be installed for each inverter.

Battery Connection

WARNING:

• All wiring must be performed by qualified personnel according to local regulations.
• Shock Hazard. Installation must be performed with care due to the high battery voltage in series.
• System safety and efficient operation need to use appropriate cable cross-sections for the battery connection.
• The recommended cross-section for the battery connection is 50 mm² for the PLI 5000-48 and PLI 2400-24, and 25 mm² for the PLI 1000-12 (at 3 metres cable length).
• Keep the cables between the inverter and battery as short as possible, preferably ≤ 3 metres. Failure to tighten connections adequately could lead to overheating or fire.

CAUTION:

• To ensure safe operation and regulation compliance, it is necessary to install a separate DC fuse or circuit breaker device between battery and inverter, as close as possible to the battery terminal.
• The recommended fuse or circuit breaker rating is 250 Adc for the PLI 5000-48 and PLI 2400-24, and 200 Adc for the PLI 1000-12, be sure to adhere to your local regulations.
• Do not place anything between the flat part of the inverter terminal and the ring terminal. Otherwise, overheating and / or fire may occur.
• Do not apply any anti-oxidant or other substances on the terminals before the terminals are connected tightly.

Follow the steps below to connect the battery to the inverter:

1. Ensure the ON/OFF power button is set to OFF (see chapter “Power ON/OFF”).
2. Open the circuit breaker or remove the fuse near the battery terminal.
3. Remove 15 mm of insulation on the inverter side of the battery cable from both the positive and negative lines.
4. Assemble the included battery ring terminal by crimping it to the battery cables on the inverter side, make sure that none of the insulation interferes with the ring terminal!
5. Connect all battery cells or packs as required to reach 48, 24 or 12 Vdc nominal voltage for the PLI 5000-48, PLI 2400-24 and PLI 1000-12 respectively. It is highly recommended to use at least a 200 Ah capacity battery bank.
6. Connect the battery-side of the cable to the battery appropriately, ensuring a tight and reliable fit.
7. Remove the M6 nut on the positive and negative battery terminals of the inverter.
8. Insert the ring terminal of the battery cable flatly into the battery connector screws of the inverter, then tighten the M6 nuts / screws with a torque of 2 – 3 Nm (see Figure 6). Make sure the polarity at both the battery and the inverter is correct and the ring terminals are tightly screwed to the battery terminals, ensuring a good electrical connection.
9. Make sure to install a strain relief on the battery cables.
10. Do not insert the battery fuse or turn on the battery circuit breaker yet!

CAUTION:

1. An inverter with storage connections will need to provide a means for temperature compensation of the battery charge voltages.
2. This is particularly important for use with lead acid batteries in warm climates, to avoid damage to battery banks by overcharging in hot weather, and related hazards due to release of hydrogen gas and cell rupture.
3. The Steca Solarix PLI does not include a connection terminal for a remote battery temperature sensor.
4. If installing a Steca Solarix PLI with lead acid batteries please check with your local retailer or manufacturer for advice regarding charge settings.

AC Input / Output Connection

DANGER:

• Be sure that the AC power source is disconnected before attempting to hardwire it to the unit.

WARNING:

• All wiring must be performed by qualified personnel according to local regulations.
• System safety and efficient operation need to use appropriate cable cross-sections for the AC connection.
• The recommended cross-section for the AC connection is 6 mm², 2.5 mm² is sufficient for the PLI 1000-12. Failure to tighten connections adequately could lead to overheating or fire.

CAUTION:

• Before connecting to the AC input power source, install a separate AC breaker between the inverter and AC input power source and turn it off.
• This will ensure the inverter can be securely disconnected during maintenance and is protected from over-current from the AC input.
• The recommended AC breaker rating is 40 A, 30 A or 10 A for the PLI 5000-48, PLI 2400-24 and PLI 1000-12, respectively. Follow your local regulations.
• There are two terminal blocks, one marked “AC INPUT” and the other “AC OUTPUT”.
• Do NOT mix the input and output connectors! Connect a single inverter to only one phase (L and N). Also make sure never to reverse L and N connections.
• Some appliances such as air conditioners require at least 2 – 3 minutes to restart after a loss of power to have enough time for the refrigerant gas to settle.
• If a power shortage occurs and power is re-supplied in a short time, this may cause damage to such appliances.
• To prevent this kind of damage, please check the appliance manufacturer guidelines, the appliance may be equipped with a time-delay function during installation.
• If this is disregarded, this inverter may trigger an overload fault and cut off output to protect your appliances, potentially nonetheless causing internal damage to the appliance.
• It is highly recommended to use a surge protection device (SPD) on the AC input of the inverter if the AC input is used. The SPD must have a clamping voltage at or below 300 Vac.

Follow the steps below to connect the AC input (optional) and AC output to the inverter:

1. Before making AC input/output connection, ensure the battery DC circuit breaker is open and/or the battery fuse is removed, thus disconnecting the battery.
2. Ensure the AC circuit breaker is open so that no conductors have voltage.
3. Remove 10 mm of insulation on the inverter side of the PE (protective earth) conductors for both AC input and AC output. Remove 7 mm of insulation on the inverter side of the L (phase) and N(neutral) conductors for both AC input and AC output.
4. Connect the PE ( – protective earth) cable of the AC input (Figure 7) to the corresponding terminal on the inverter and connect the PE ( – protective earth) conductor of the AC output (Figure 8) to the corresponding terminal on the inverter. Tighten the terminal clamps with a torque of 1.2 Nm.
5. Connect the L (phase) and N (neutral) conductors to the respective AC input (Figure 7) and AC output (Figure 8) terminals. Tighten the terminal clamps with a torque of 1.2 Nm.
6. Make sure to install a strain relief on the AC input and AC output cables.
7. Make sure all connections are secure and tightened correctly, ensuring a good electrical connection.

PV Connection

WARNING:

• All wiring must be performed by qualified personnel according to local regulations.
• System safety and efficient operation need to use appropriate cable cross-sections for the PV connection.
• The recommended cross-section for the PV connection is 12 mm² or 6 mm² for the PLI 5000-48 or PLI 2400-24 / PLI 1000-12, respectively. Failure to tighten connections adequately could lead to overheating or fire.

CAUTION:

• Before connecting to the PV input, install a separate DC breaker or DC disconnecting switch with a recommended rating of at least 80 Adc (PLI 5000-48) or 40 Adc (PLI 2400-24 and PLI 1000-12) between the inverter and PV modules and turn it off.
• This will ensure the inverter can be securely disconnected during maintenance.
• It is highly recommended to use a surge protection device (SPD) on the PV input of the inverter, if the PV input is used, to protect the PV input from over-voltage.
• The SPD must have a clamping voltage at or below 160 Vdc (PLI 5000-48) or 100 Vdc (PLI 2400-24 and PLI 1000-12), and above the maximum open-circuit PV voltage under all temperature conditions at the installation site.

PV Module Selection
When selecting proper PV modules, please be sure to consider the following parameters:

1. The open-circuit voltage (Voc) of the PV array at the lowest temperatures present throughout the year in the installation location does not exceed the maximum PV open-circuit voltage of the PV input of the inverter.
2. The MPP voltage (Vmpp) of the PV array must be higher than the minimum PV MPP voltage of the PV input of the inverter.
3. The total power in watt-peak (Wp) of the PV array should not exceed 1.2x the nominal PV charging power of the inverter.

Follow the steps below to connect the PV input (optional) to the inverter:

1. Ensure the circuit breaker between the PV modules and the inverter side of the PV cables is open so that there is no voltage on the PV cables before the connection.
2. Remove 10 mm of insulation on the inverter side of the battery cable from both the positive and negative PV cables.
3. Check the correct polarity of the connection cable from the PV modules and PV input connectors on the inverter.
4. Connect the positive and negative cables from the PV array to the respective PV terminals on the inverter (Figure 9). Tighten the terminal clamps with a torque of 1.2 Nm
5. Make sure the connections are secure and tightened correctly, ensuring a good electrical connection.

Final Assembly

After connecting all wirings, please slide the bottom cover back onto the bottom of the inverter and fasten the two screws as shown below (Figure 10).

Now the fuse/circuit breaker of the battery can be inserted/closed to electrically connect the inverter to the battery. Next, the AC input circuit breaker can be closed, then the AC output breaker and finally the fuse/circuit breaker of the PV connection.
Optional Accessories

• The Solarix PLI 5000-48 and Solarix PLI 2400-24 can be used with up to nine identical inverters in a single synchronised phase, or set up as a 3-phase system.
• This allows systems with up to 45 kW or 21.6 kW of synchronised AC power for the Solarix PLI 5000-48 or Solarix PLI 2400-24, respectively.
• To enable this functionality, the Steca Parallel Kit for Solarix PLI is required (sold separately).
• One kit is required for each inverter to be interconnected. For further details consult the Parallel Kit manual.

Dry Contact Signal

• There is a dry contact (up to 3 A / 250 V AC or 3 A / 30 V DC) available on the bottom panel.

It has two possible functions:

1. When program 38 is set to “disable” (see chapter “Configuration”), it can be used to deliver a signal to an external device (such as an AC generator) when the battery voltage reaches its warning level.
2. When program 38 is set to “enable” (only available for Solarix PLI 5000-48) and the unit is working in battery/inverter mode, it can be used to trigger an external grounding box (not included). This grounding box can then connect the neutral (N) and protective earth (PE) grounding of the AC output together.

Function 2 is useful for grid-tied installations where the AC input has a TN-C-S or TN-S grounding scheme, so where PE and N are separate and typically a residual current device (RCD) is used for safety from electric shock. For an RCD on the AC output to function, there must be a bridge between N and PE before it. This is the case in a TN-C-S or TN-S grounding scheme. As a safety measure, when the inverter is working in off-grid / inverter mode, when both the AC input N and L are disconnected by the internal by-pass / transfer relay, a connection between N and PE is automatically made in the PLI 5000-48 and PLI 2400-24 inverters. With program 38 enabled, an external grounding box controlled by the dry contact can bridge N and PE only in off-grid / inverter mode and release the bridge in line/grid mode, as an additional N to PE bridge. Grounding is safety-relevant and should only be done by qualified personnel. Make sure local regulations are adhered to. When program 38 is set to “disable” (default setting for PLI 5000-48 and PLI 1000-12, only setting for PLI 2400-24):

Inverter unit status| Condition| Dry contact port:
---|---|---
NC & C| NO & C
Power Off| Unit is off and no output is powered.| Closed| Open
Power On| Output is powered from AC input.| Closed| Open
Output is powered from Battery or Solar.| Program 01 set to “Utility”| Battery voltage < Low DC warning voltage| Open| Closed
Battery voltage > value set in Program 13 or battery charging reaches floating stage| Closed| Open
Program 01 is set to “SBU” or “Solar first”| Battery voltage < value set in Program 12| Open| Closed
Battery voltage > value set in Program 13 or battery charging reaches floating stage| Closed| Open

When program 38 is set to “enable” (only available for PLI 5000-48 and PLI 1000-12):

Fern Lite

Installation Manual Pre-installation Requirements

• Step 1
  • Connect FernLite to your master inverter’s RS-232 port using the white cable. Find the MAC address on your FernLite device.
• Step 2
  • Register your FernLite at https://fernview.odysseyenergysolutions.com/register. After typing in your MAC address choose the ‘Register’ option.
• Step 3
  • Fill in the details on the form and click ‘Register’.
• Step 4
  • Activate your account by verifying the email in your inbox. Follow the instructions to create a new password. If you can’t find the verification email, contact fernsupport@odyssey.energy.
• Step 5
  • Login to the FernView portal https://fernview.odysseyenergysolutions.com/login. with your email address and new password.

FernLite Configuration

• Step 1
  • To install the FernLite device, follow these steps after accessing the FernView portal:
  • Select ‘Controllers’ on the left side menu
  • Select the ‘FernLites’ option
  • Click on the three dots on the right side of the screen, along the line of your newly added device
  • Click on ‘Install’ from the drop-down menu
• Step 2
  • Upon clicking ‘Install’, you will be directed to the initial step of the FernLite installation page.
  • Generate FernLite Configuration To set up your FernLite device, follow these steps:
  • Under the ‘General Configuration’ section, enter your local WiFi name and password (2.4GHz bandwidth required).
  • Click ‘Download’ on the screen
  • Once the file is downloaded, connect to your FernLite network from the available WiFi options on your computer, with the last 4 digits of the network name matching your FernLite’s MAC number.
  • For example, the name of your network can be EW11_3A32 if your FernLite MAC address is ****3A32. Ignore the ‘no internet connection’ prompt during installation; it is normal and can be disregarded.
  • Navigate to IP address 10.10.100.254 in a new browser tab after connecting to the FernLite network. Sign in using the following credentials: Username: admin; Password: admin
  • The FernLite configuration page appears after signing in.
• Step 3
  • Follow the steps below to proceed with the installation process:
  • Click the ‘Others’ option on the left menu
  • Under the backup/restore configuration section, select ‘Choose file’
  • Upload the previously downloaded file (stored under the name ‘FernLite_config.xml’. For: e.g. FernLite 439C6G1237A2_config.xml).
  • Click ‘Start’ once the file has been uploaded
  • Confirm restoring all configuration by clicking ‘OK’ in the pop up window asking if you are sure to restore all configuration
  • The window will now indicate that it is ‘Restarting’
  • At this point you will lose the WiFi connection to the FernLite. Reconnect to your original WiFi network to regain internet access. To confirm FernLite’s connection to the WiFi network, observe the LED light on the RJ45 port:
  • If the FernLite is newly powered up and not yet connected to WiFi, the LED light will continuously blink fast (flashes every second).
  • Once FernLite is connected to WiFi, the LED light will flash slowly (flashes once every 3 seconds).
• Step 4
  • After configuring FernLite, resume the installation process by returning to the FernView portal tab once you’ve reconnected to your local WiFi network.
  • The FernLite system configuration is successful and connected to your local network when the page displays ‘Your FernLite system is currently in OK state’. It may take a minute to detect.
  • Click ‘Next’ to continue the installation once FernLite is successfully connected.
  • FernLite is now successfully installed.

Operation

Power ON/OFF

Once the unit has been correctly installed and the batteries are well connected, simply press the ON/OFF switch in Figure 11 to the ON position (located on the button of the case) to turn on the inverter.

Display and Control Panel

• The operation and display panel, shown in Figure 12, is on the front panel of the inverter.
• It includes three LED indicator lamps, four function buttons and an LC-display, indicating the operating status.

LED Indicators

Function Buttons

LC-Display Icons

Configuration

CAUTION:

• Consult your battery manufacturer’s documentation to determine the optimal battery settings.
• KATEK Memmingen GmbH cannot be held responsible for incorrect battery settings or battery settings that are incompatible with the particular battery in use.
• After pressing and holding the “ENTER” button for 3 seconds, the unit will enter its configuration/setting mode.
• Press the “UP” or “DOWN” button to select different setting programs. Then press the “ENTER” button to confirm the selection or “ESC” to exit.

Setting Programs:

Any setting programs not explicitly mentioned in this chapter are irrelevant when using a single unit and should not be changed!

Display Setting

• The LCD information can be cycled by pressing the “UP” or “DOWN” button.
• The selectable information is cycled in this order: input voltage, input frequency, PV voltage, charging current, charging power, battery voltage, output voltage, output frequency, load percentage, load in VA, load in Watt, DC discharging current, main CPU version and second CPU version.
• The values shown are examples only and are not necessarily valid for all inverter models.

Operating Mode Description

Recommendation for generator as AC input source
Since in grid mode the generator not only supplies the loads at the AC output but also recharges the battery, it is generally recommended to use a generator with twice the size of the inverter.
Further technical requirements of the generator:

• Generator waveform THD: < 30%. If the generator outputs a square wave, output duty should greater than 60%
• Generator Vrms range: 100 ~ 270Vac
• Generator voltage crest factor(Vpeak/Vrms): < 1.6
• Generator peak voltage: <380V
• Generator frequency range: 45Hz ~ 63Hz
• Generator frequency slew rate: < 0.3Hz/sec

Internal Fan

• As the power density of the Solarix PLI is very high, the fans are always running at low speed to keep the air moving at about ¼ speed.
• The fans are PWM controlled and operate proportionally to the inverter / PV power. This is to cool the power components before heat-buildup occurs in the first place.
• If the environment is sensitive to noise we advise to install in a closed room with sufficient cooling.

Fault Reference Code

Warning Reference Code

Battery Equalisation

The charge controller is equipped with an equalisation function. It reverses the buildup of negative chemical effects like stratification, a condition where acid concentration is greater at the bottom of the battery than at the top. Equalization also helps to remove sulfate crystals that might have built up on the plates. If left unchecked, this condition, called sulfation, will gradually reduce the overall capacity of the battery. Therefore, it is recommended to equalise battery periodically if it is a flooded / liquid- electrolyte type lead-acid battery. Refer to your battery manual or manufacturer for compatibility.

How to Apply the Equalisation Function
The function can be enabled in program 33, chapter “Configuration”. Once the equalisation function is enabled it can be configured with the following parameters:

1. “Equalisation voltage” in program 34, chapter “Configuration”. This defines the desired battery voltage during the equalisation phase.
2. “Equalisation duration” in program 35, chapter “Configuration”. This defines the duration of the equalisation program in minutes.
3. “Equalisation timeout” in program 36, chapter “Configuration”. This defines the maximum duration of the equalisation program in minutes. The duration may be prolonged due do voltage fluctuations at the battery or insufficient power from the charger. This timeout ensures that the equalisation process is stopped, at the latest after the timeout has elapsed.
4. “Equalisation interval” in program 37, chapter “Configuration”. Once the equalisation is completed this interval defines when the charger automatically proceeds with the next equalisation cycle.
5. “Battery equalisation activated / forced immediately“ in program 39, chapter “Configuration”.

When Equalisation takes place
In the float charging stage, once the equalisation interval is reached, or equalisation is forced immediately with program 39 in the chapter “Configuration”, the charge controller will start to enter the equalisation phase (see Figure 12).

Equalisation duration and timeout
In the equalisation phase, the charge controller will supply power to charge the battery as much as possible until the battery voltage raises to battery equalisation voltage defined in program 34 in the chapter “Configuration”. Then, constant-voltage regulation is applied to maintain the battery voltage at the battery equalisation voltage level. The battery will remain in the equalisation phase until the equalisation duration in program 35 in the chapter “Configuration” has elapsed (see Figure 12). However, during the equalisation phase, once the equalisation duration has elapsed and if the battery voltage has not reached the equalisation voltage, the charge controller will extend the battery equalisation phase time until the battery voltage reaches the equalisation voltage. If battery voltage is still lower than the equalisation voltage once the equalisation timeout has elapsed, the charge controller will exit the equalisation phase and return to float phase (see Figure 13).

Specifications

Line Mode Specifications

Inverter model| Solarix PLI 5000-48| Solarix PLI 2400-24| Solarix PLI 1000-12
---|---|---|---
Input Voltage Waveform| AC sinusoidal (utility or generator)
Nominal AC Input Voltage *| 230 Vac
Min. Input Voltage Cut-Off| 170 Vac ± 7 V (UPS mode)

90 Vac ± 7 V (Appliances mode)

Min. Input Voltage Return| 180 Vac ± 7 V (UPS mode) 100 Vac ± 7 V (Appliances mode)
Max. Input Voltage Cut-Off| 280 Vac ± 7 V
Max. Input Voltage Return| 270 Vac ± 7 V
Absolute Max. AC Input Voltage| 300 Vac
Nominal Input Frequency *| 50 Hz / 60 Hz (Auto detection)
Min. Input Frequency Cut-Off| 40 Hz ± 1 Hz
Min. Input Frequency Return| 42 Hz ± 1 Hz
---|---
Max. Input Frequency Cut-Off| 65 Hz ± 1 Hz
Max. Input Frequency Return| 63 Hz ± 1 Hz
AC Output Short-Circuit Protection| Line mode: Circuit Breaker rated at 40 A Battery mode: Electronic Protection (see program 06 in chapter „ Configuration “)| Line mode: Circuit Breaker rated at 30 A Battery mode: Electronic Protection (see program 06 in chapter „ Configuration “)| Line mode: Circuit Breaker rated at 10 A Battery mode: Electronic Protection (see program 06 in chapter „ Configuration “)
Efficiency between AC input and AC output (Line Mode)|  | ****

| ****

99%

|
Transfer Time between line mode and battery mode *| 10 ms typical (UPS mode)

20 ms typical (Appliances mode)

Output power de-rating:| In Line Mode the maximum load current is always 40 A. Therefore the available maximum power depends on the actual AC input voltage. For example at an input voltage of 230 Vac x 40 A = 9.2 kW. And an input voltage of 170 Vac x 40 A = 6.8 kW.| In Line Mode the maximum load current is always 30 A. Therefore the available maximum power depends on the actual AC input voltage. For example at an input voltage of 230 Vac x 30 A = 6.9 kW. And an input voltage of 170 Vac x 30 A = 5.1 kW.| In Line Mode the maximum load current is always 10 A. Therefore the available maximum power depends on the actual AC input voltage. For example at an input voltage of 230 Vac x 10 A = 2.3 kW. And an input voltage of 170 Vac x 10 A = 1.7 kW.

As soon as a valid voltage and frequency is detected at the AC input, the inverter will synchronise its AC output frequency to the input in battery mode. This is to avoid a frequency mismatch between the AC input and AC output and to enable the fast switching times typical of uninterruptible power supplies (UPS).
Inverter / Battery Mode Specifications

Inverter model| Solarix PLI 5000-48| Solarix PLI 2400- 24| Solarix PLI 1000- 12
---|---|---|---
Rated Output Power| 5000 W / 5000 VA| 2400 W / 3000 VA| 1000 W / 1200 VA
Output Voltage Waveform| Pure sine wave
Output Voltage Regulation| **** 230 Vac ± 5%| 220, 230 or 240 Vac ± 5% (selectable)| 230 Vac ± 5%
Output Frequency| 50 Hz or 60 Hz (selectable)
Efficiency (DC to AC)| > 93% peak

efficiency, > 91% efficiency between 20% and 100% of nominal output power at 48 Vdc battery

voltage

| > 91% peak

efficiency, > 90% efficiency between 30% and 100% of nominal output power at 24 Vdc

battery voltage

| 90% peak efficiency,

88% efficiency

between 30% and

85% of nominal output power at 12 Vdc battery voltage

---|---|---|---
Overload Protection / Disconnect| 5 seconds at ≥ 150% load; 10 seconds at 110% ~ 150% load
Surge Capacity| 2 x rated power for 5 seconds
Nominal Battery Input Voltage| 48 Vdc| 24 Vdc| 12 Vdc
Minimum battery voltage for

power up of inverter

| 46.0 Vdc| 23.0 Vdc| 11.5 Vdc
Low Battery Warning Voltage at load < 20%

at 20% ≤ load < 50%

at load ≥ 50%

| 44.0 Vdc

42.8 Vdc

40.4 Vdc

| 22.0 Vdc

21.4 Vdc

21.4 Vdc

| 11.0 Vdc

10.7 Vdc

10.1 Vdc

Low Bat. Warning Return Voltage at load < 20%

at 20% ≤ load < 50%

at load ≥ 50%

| 46.0 Vdc

44.8 Vdc

42.4 Vdc

| 23.0 Vdc

22.4 Vdc

21.2 Vdc

| 11.5 Vdc

11.2 Vdc

10.6 Vdc

Low Battery Cut-off Voltage (only valid for “AGM / Gel” or “Flooded” battery types in Program 05)

at load < 20%

at 20% ≤ load < 50% at load ≥ 50%

| 42.0 Vdc

40.8 Vdc

38.4 Vdc

| 21.0 Vdc

20.4 Vdc

20.4 Vdc

| 10.5 Vdc

10.2 Vdc

9.6 Vdc

High Battery Cut-off Voltage| 66 Vdc| 30 Vdc| 15.5 Vdc
High Battery Recovery Voltage| 62 Vdc| 29 Vdc| 14.5 Vdc
No Load Power Consumption| < 50 W| < 45 W| < 17 W
Saving Mode Power Consumption| < 15 W| < 14 W| < 4 W

Charge Mode Specifications

Utility / AC and PV Charging Modes

Inverter model| Solarix PLI 5000- 48| Solarix PLI 2400-24| Solarix PLI 1000-12
Maximum Charging Current from AC Source| 60 Adc| 20 Adc
Boost Charging Voltage| Flooded Battery| 58.4 Vdc| 29.2 Vdc| 14.6 Vdc
AGM / Gel Battery| 56.4 Vdc| 28.2 Vdc| 14.1 Vdc
Floating Charging Voltage|  |  |
---|---|---|---
(Flooded or AGM / Gel Battery| 54 Vdc| 27 Vdc| 13.5 Vdc
setting)|  |  |
Overcharge Protection| 66 Vdc| 30 Vdc| 15.5

Solar / PV Charging Mode

Inverter model

| Solarix PLI 5000-

48

| Solarix PLI 2400-

24

| Solarix PLI 1000-

12

Rated Power| 4800 W| 1168 W| 550 W
Efficiency| 98% max.; ≥ 96% between 1 kW and 4 kW PV power at ~ 90 Vmpp PV voltage| 98% max.; ≥ 95% between 100 W and 900 W PV power at ~ 60 Vmpp PV voltage| 95% max.; ≥ 85% between 100 W and 550 W PV power at ~ 60 Vmpp PV voltage
Max. PV Array Open Circuit Voltage| 145 Vdc| 100 Vdc| 100 Vdc
PV Array MPPT Voltage Range| Minimum 60 Vdc, recommendation 68 ~ 115 Vdc| Minimum 30 Vdc,

recommendation 34 ~ 80 Vdc

| Minimum 15 Vdc,

recommendation 17 ~ 80 Vdc

Min. battery voltage for PV charging| 34 Vdc| 17 Vdc| 8.5 Vdc
Standby Power Consumption| 2 W
Battery Voltage Measurement Accuracy|  | ****

+/-

| ****

0.3%

|
PV Voltage Measurement Accuracy| +/- 2 V
Simultaneous Utility / AC and Solar / PV Charging

Maximum Charging Current| 140 A| 100 A| 60 A
Default Charging Current| 80 A| 60 A| 40 A

General Specifications

Inverter model| Solarix PLI 5000-48| Solarix PLI 2400- 24| Solarix PLI 1000- 12
---|---|---|---
Safety & EMC Certification| CE, for further details, visit www.steca.com
Operating Temperature Range| 0 °C to 55 °C, derating from 40 °C
Storage Temperature| -15 °C ~ 60 °C
Degree of Protection| IP 21
Humidity| 5 % to 90 % relative humidity (non-condensing)
Operating Altitude| 1000 m a.s.l., 1% nominal power derating per 100 m over 1000 m
AC Terminal (fine/single wire)| 6 mm² / AWG 8
PV Terminal (fine/single wire)| 10 mm² / AWG 6| 6 mm² / AWG 8
Battery connection (fine wire)| 35 mm² … 50 mm² / AWG 2 … AWG 0| 25 mm² / AWG 3
Dimension (width x height xdepth)| 298 x 469 x 130 mm| 275 x 385 x 114mm| 243 x 331 x 115
Net Weight| 11.5 kg| 7.6 kg| 6.9 kg

Troubleshooting

Shutdown procedure

When a fault is detected, the inverter will often times shut down automatically to prevent further complications. This is followed by a restart of the unit. If you encounter a fault which requires a manual or emergency shutdown please adhere to the following steps:

• Shut down the inverter unit using the power button
• If available switch off attached fuses in the PV input, AC input and battery connections
• Contact your local retailer for support. They will help you with any issues you may have.

CAUTION: The unit is not fully shut down until the PV input, AC input and battery connections are properly separated and disconnected.

Maintenance

• Except for the care of its exterior, the inverter does not require maintenance.
• Remove dust with compressed air (max. 2 bar)
• Remove soiling with a dry cloth. Using a damp or even wet cloth can damage the inverter.
• WARNING: Shock Hazard. Maintenance must be performed with care due to high battery voltage in series.
• Shut down the inverter before any cleaning procedures.
• Only use a dry cloth to clean the outside of the inverter.
• Do not clean the insides of the inverter.
• Any repair work may only be carried out by the manufacturer’s customer service department

Troubleshooting

Problem

| LCD / LED /

Buzzer

| Explanation /

Possible cause

| ****

What to do

---|---|---|---
The unit shuts down automatically during start-up process.| LCD/LEDs and buzzer will be active for 3 seconds and then completely shut-off.| The battery voltage is too low

(< 1.91 V / Cell)

| 1.  Re-charge battery.

2.  Replace battery.

No response after power on.| No indication.| 1.  The battery voltage is far too low (< 1.4 V / Cell)

2.  Battery polarity

reversed

| 1.  Check if batteries and the wiring are correctly connected.

2.  Re-charge battery.

3.  Replace battery.

 | Input voltage is|  |
 | displayed as 0 on| Input protector is| Check if AC breaker is tripped and AC
 | the LCD and green| tripped| wiring is correctly connected.

AC input is active but the unit only works in battery mode.

| LED is flashing.|  |
Green LED is flashing.| Insufficient quality of AC power (mains power or generator)| 1.  Check if AC wires are too thin and/or too long.

2.  Check whether generator (if applied) is working well or if input voltage range

setting is correct (switch from “UPS” to

 |  |  | “Appliances” in settings program 03).
 | Green LED is| “Solar First” set as| Change the output source priority to
 | flashing.| prio. of output source| “Utility first”.
When the unit is turned on, the internal relay is switched on and

off repeatedly.

| LCD display and LEDs are flashing.| Battery is disconnected| Check if battery fuse & wires are correctly connected.
---|---|---|---
Buzzer beeps continuously and red LED is on.| Fault code 07| Overload error. The inverter is overloaded to ≥ its nominal power and the overload timeout has

elapsed.

| Reduce the connected load by switching off some loads.
Fault code 05| Output short-circuited| Check if the wiring is correctly connected and remove the abnormal load.
Fault code 03| Battery is over-charged| Check if there are any external chargers directly connected to the battery. If not, contact your dealer.
The battery voltage is too high| Check if the specification and quantity of batteries meet the necessary requirements.
Fault code 02| Internal temperature of inverter components is over 100 °C| Check whether the air flow of the unit is blocked or whether the ambient temperature is too high.
Fault code 01| Fan fault| Contact your dealer.
Fault code 06/58| AC Output abnormal (inverter voltage < 190 Vac or > 260

Vac)

| 1.  Reduce the connected load.

2.  Contact your dealer.

Fault code

08/09/53/57

| Internal components failed| Contact your dealer.
Fault code 51| Over-current or surge| Restart the unit, if the error happens again, please contact your dealer.
Fault code 52| DC Bus voltage is too

low

Fault code 55| Output voltage is

unbalanced

Fault code 56| The battery is not connected correctly or the battery fuse is burnt| If the battery is connected correctly, please contact your dealer.

Guarantee Conditions

Conditions are available on the Internet at: https://www.steca.com/index.php?5_Jahre_Garantie5ea97a3a7b893.

Exclusion of Liability

• The manufacturer can neither monitor the compliance with this manual nor the conditions and methods during the installation, operation, usage and maintenance of the controller.
• Improper installation of the system may result in damage to property and, as a result, to bodily injury.
• Therefore, the manufacturer assumes no responsibility and liability for loss, damage or costs which result from or are in any way related to incorrect installation, improper operation, incorrect execution of installation work and incorrect usage and maintenance.
• Similarly, we assume no responsibility for patent right or other right infringements of third parties caused by usage of this controller.
• The manufacturer reserves the right to make changes to the product, technical data or installation and operating instructions without prior notice.

Contact

In the case of complaints or faults, please contact the local dealer from whom you purchased the product. They will help you with any issues you may have.

• KATEK Memmingen GmbH
• Mammostrasse 1
• 87700 Memmingen
• Germany
• E-mail service@stecasolar.com.
• Internet www.steca.com.
• Steca Solarix PLI Instructions, Page 42

Did you know?

• This inverter can be linked to a remote monitoring solution.
• For more information, scan this:

Documents / Resources

| Steca Solarix PLI Inverter Hybrid Charger [pdf] Instruction Manual
Solarix PLI Inverter Hybrid Charger, Solarix PLI, Inverter Hybrid Charger, Hybrid Charger, Charger
---|---

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