tbs electronics OCS 100-20 Le manuel du propriétaire

MPPT Solar Charge Controller

Omnicharge Solar

OCS 100-20 (100V/20A)

OCS 100-30 (100V/30A)

OCS 100-50 (100V/50A)

Owner’s manual

Gebruikershandleiding

Bedienungsanleitung

Mode d’emploi

Manual de usuario

TBS ELECTRONICS BV

De Marowijne 3, 1689AR, Zwaag, The Netherlands

tbs-electronics.com

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Notice of Copyright

rights reserved. No part of this document may be reproduced in any form or disclosed to third

parties without the express written permission of TBS Electronics BV, De Marowijne 3, 1689AR,

Zwaag, The Netherlands. TBS Electronics BV reserves the right to revise this document and to

periodically make changes to the content hereof without obligation or organization of such revisions

or changes, unless required to do so by prior arrangement.

Exclusions for documentation and product usage

UNLESS SPECIFICALLY AGREED TO IN WRITING, TBS ELECTRONICS BV (“TBS”) :

1. MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY

TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER

DOCUMENTATION

2. ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,

WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT

ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION

WILL BE ENTIRELY AT THE USER’S RISK

3. REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH OR

DUTCH, ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE

TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED.

4. MAKES NO WARRANTY, EITHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE,

REGARDING THESE TBS PRODUCTS AND MAKES SUCH TBS PRODUCTS AVAILABLE SOLELY ON AN

“AS IS” BASIS.

5. SHALL IN NO EVENT BE LIABLE TO ANYONE FOR SPECIAL, COLLATERAL, INCIDENTAL, OR

CONSEQUENTIAL DAMAGES IN CONNECTION WITH OR ARISING OUT OF PURCHASE OR

USE OF THESE TBS PRODUCTS. THE SOLE AND EXCLUSIVE LIABILITY TO TBS, REGARDLESS

OF THE FORM OF ACTION, SHALL NOT EXCEED THE PURCHASE PRICE OF THE TBS

PRODUCTS DESCRIBED HERE IN.

Document name, date and part number

“OCS-20-50 User Manual Rev1endfs”, August 2023, xxxxxx

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English

Page 5

Nederlands

Pagina 25

Deutsch

Seite 44

Francais

Page 65

Español

Página 85

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TABLE OF CONTENTS

TABLE OF CONTENTS.............................................................................................................................. 5

1. SAFETY PRECAUTIONS ........................................................................................................................ 6

2. TECHNOLOGY ..................................................................................................................................... 7

2.1 Product features ...................................................................................................................... 7

2.2 MPPT charging ......................................................................................................................... 7

2.3 Battery charging explained ..................................................................................................... 9

2.4 Temperature compensation ................................................................................................. 10

3. OMNICHARGE SOLAR SETUP............................................................................................................ 11

3.1 Using the Dashboard Mobile app.......................................................................................... 11

3.2 Setting up the Omnicharge Solar charger ............................................................................. 15

3.2.1 Creating a lithium charge program with a float stage ....................................................... 16

3.3 Overview of factory default charge program parameters .................................................... 17

4. TROUBLESHOOTING GUIDELINE ...................................................................................................... 18

5. TECHNICAL SPECIFICATIONS ............................................................................................................ 21

5.1 Dimension drawings .............................................................................................................. 22

6. WARRANTY CONDITIONS ................................................................................................................. 23

7. DECLARATION OF CONFORMITY ...................................................................................................... 24

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1. SAFETY PRECAUTIONS

Thank you for purchasing a TBS Electronics (TBS) Omnicharge Solar MPPT Solar Charge Controller

(hereinafter referred to as 'product' or ‘solar charger’). Please read this user manual for information

about operating the product correctly and safely.

!

CAUTION

This user manual is an addition to the installation manual of this product. Please make sure

that the installation manual has always been read first, before proceeding with the user

manual. The installation manual is included with the charger or can be downloaded from

our website at tbs-electronics.nl/downloads.

Keep this user manual and all other included documentation close to the product for future

reference. For the most recent manual revision, please check the downloads section of our website.

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2. TECHNOLOGY

2.1 Product features

Omnicharge Solar battery chargers are true next generation products and contain the latest highly

efficient switch mode power supply technology, as well as a smart digital control system. Please see

below a summary of the most important Omnicharge Solar features:

• Fast Maximum Power Point Tracking (MPPT) ensures that you always get the maximum

amount of power transferred from the PV panels to your battery. Even under the most

difficult circumstances. The MPPT efficiency of an Omnicharge Solar charger can reach up to

99%.

• Highly efficient switch power supply technology ensures a low waste of power and allows for

a fan-less design.

• Smart selectable charge programs for AGM, Gel, Flooded, Lithium and User defined battery

types

• Automatic battery voltage detection

• Battery temperature sensor input

• Historical data storage up to 300 days

• Full protection against battery reverse polarity, PV reverse polarity, short circuits, battery

open circuit and solar charger over temperature

• Monitoring and configuration via Dashboard Mobile app (iOS and Android)

2.2 MPPT charging

There are essentially two types of charging technologies for solar chargers. These are PWM and

MPPT technology. PWM is the most basic one and can be seen as just an automatic switch that

connects the PV array directly to the battery as long as charging is needed. This results in a PV

voltage that is pulled down to the same level as the battery voltage. And since this voltage level is

typically lower than the maximum power point voltage (Vmp) of the PV array, the resulting effective

power to charge the battery bank is not optimal.

A solar charger with MPPT technology is more advanced and it is based on a smart high efficiency DC

to DC converter that will continuously find the maximum amount of power that is available from the

PV array. This is accomplished by varying the input voltage of the charger by controlling the amount

of power consumed from the PV array. The main goal is to find the highest result out of the

multiplication of battery voltage and charging current (P = V * I). This highest result is called the

Maximum Power Point. The image below shows a typical I-V graph of a PV panel. Added in red is a

scaled graph representing the generated power (multiplication of I and V) of the same PV panel,

including the maximum power point Pmax:

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The blue area in the above graph (ΔP) represents the typical operating area of a traditional PWM

type solar charge controller. As you can see, Pmax (MPPT) is higher than ΔP (PWM).

The fast and efficient MPPT technology onboard of the Omnicharge Solar products makes sure that

the maximum power point is tracked continuously. This is to make sure that it always operates at the

maximum power point of the PV array, that may vary continuously against irradiation levels from the

sun, partial shading (causing more than one Pmax point) and last but not least PV array temperature.

In general, a well designed MPPT solar charge controller will typically get 15 – 25% more power from

your PV array compared to traditional PWM type solar chargers.

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2.3 Battery charging explained

Most standard selectable Omnicharge Solar charge programs perform a 3-stage IUoUo charging

process comprising of a “Bulk/MPPT” , an “Absorption/Boost”, and a “Float” stage. All of course for

as long as there is sufficient sunlight. The image below visualizes the 3-stage charging process:

In the Bulk/MPPT stage the charger delivers full available output current and typically returns

approximately 80% of charge back into the battery, once the charge voltage is reached. During this

stage the charger runs in MPPT mode, transferring maximum PV power into the battery.

When the Charge voltage has been reached, the Absorption/Boost stage will be entered. In this

stage the voltage will be held constant and the current will decline automatically as function of the

battery’s state of charge. Typically, this stage will return the final 20% of charge to battery. When the

absorption time-out of 2 hours (= factory default) has been reached the float stage will be entered.

For lithium batteries the charger will remain in the absorption stage as long as there is sufficient

solar power available.

Once every 30 days and only if a Flooded (open lead acid type) battery is selected, the Omnicharge

Solar charger will automatically perform a mild equalization charge, setting the Absorption/Boost

voltage 0.4V @ 12V or 0.8V @ 24V higher than the normal voltage level for a maximum of 2 hours.

This process will help minimize the acid stratification and sulfation that typically occurs in all flooded

batteries. When you do not wish to have this automatic mild equalize charge performed on your

Flooded batteries or wish to alter the equalization voltage level, please create a user defined /

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custom charge program (see chapter 3.2) and select it to become the standard charge program. By

default mild equalization is never performed on AGM, GEL or Lithium batteries.

!

CAUTION

During a mild equalize charge, the applied voltage to the battery is higher than the standard

charge voltage. Please check if the battery and the connected battery loads can handle this

voltage safely.

After the Absorption/Boost stage has been finished and when an AGM, GEL or Flooded battery

selected, the charger will jump to the Float stage. In this stage the battery voltage will be held

constant at a safe level for the battery. This will maintain the battery in optimal condition for as long

as there is sufficient sunlight. Connected battery loads will be directly powered by the charger up to

the charger’s maximum output current level. When even more current is drawn, the battery must

supply this which results in a declining battery voltage. At a certain battery voltage level (Restart

voltage), the charger jumps back to the Bulk/MPPT stage and will execute a complete charge process

again.

By default, the Float stage is not enabled when a Lithium battery is selected. When you do need to

Float charge your Lithium battery, please create a user defined / custom charge program (see

chapter 3.2) and select it to become the standard charge program.

2.4 Temperature compensation

When the optional battery temperature sensor (art# 5055319) is connected to the Omnicharge Solar

charger and an AGM, GEL or Flooded battery is selected, it will automatically provide charge voltage

compensation against temperature. The charge voltage is compensated by -3mV/°C/cell with +25°C

as a ‘no compensation’ starting point. So for a 12V battery (6 cells) the charge voltage will increase

by +18mV/°C below 25°C and decrease by -18mV/°C above 25°C. For a 24V battery (12 cells) this is

respectively +36mV/°C and -36mV/°C.

When no battery temperature sensor is connected to the charger, the charge voltages will remain

unchanged at the default set 25°C values, independent of ambient temperature.

When a Lithium battery is installed and a temperature sensor is connected to the charger, there is no

charge voltage compensation as this is typically not allowed for this type of battery.

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3. OMNICHARGE SOLAR SETUP

All information on how to commission the Omnicharge Solar charger, how to interpret the LED

indicators on the device and how to select the battery type using the setup button on the device

itself, is explained in chapter 3 of the installation manual. This manual is included with the charger or

can be downloaded from our website at tbs-electronics.nl/downloads. For a more advanced setup

and insight in real time parameter data, please use our Dashboard Mobile app.

3.1 Using the Dashboard Mobile app

The easiest way to setup your Omnicharge Solar charger is to use the TBS Electronics Dashboard

Mobile app. You can find this app in the Apple App Store and Google Play. Besides setting up the

charger, this app will also provide you with real time information about the chargers’ operation and

access to historic data like solar energy yield and maximum power per day. The global operation of

the Dashboard Mobile app is explained below using the iOS version. The Android version will

however be very similar with only some differences in the system messages when making a

Bluetooth connection. For Android, do make sure that you also allow Location Permission and select

‘Precise’ and ‘While using the app’ after that. (TBS Dashboard does not locally or externally store any

personal, usage or location data)

Once the app is installed and launched you

will see the screen as shown on the right.

Please press ‘Allow’ to confirm acceptance

of this notifications request.

After that, please press the ‘Add Device’

button at the bottom of the screen.

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When the app is used for the first time and

right after the ‘Add Device’ button is

pressed, it will ask for permission to use

Bluetooth on your device.

Please press ‘OK’ to proceed so that the app

can scan for TBS devices in the

neighborhood.

NOTE: Bluetooth in general has a limited

range. In open spaces (line of sight) the

maximum distance between charger and

mobile device can be up to 20 meters.

However, in practical circumstances like

inside houses, vehicles or boats, several

objects such as walls or other equipment

can limit this range down to only a few

meters. On top of this, it also depends on

the Bluetooth hardware inside your mobile

device.

After the app has found a TBS Bluetooth

device, please press on it to establish a

connection.

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Now the device is shown in the Device List.

The green bar on the left side of the tile

indicates that it is successfully connected.

There are three other color states available,

being:

• Orange – Device busy connecting

• Red – Connection error

• Dark grey (Off) – No connection

This device tile will always remain in the

Device List for future use, even when it is

disconnected. So next time you launch the

app, you only have to press the device tile

and it connects automatically. You can

remove it by swiping the tile to the left and

press Delete.

When you press the device tile the app will

jump the device’s main screen.

In main screen of the device you can

observe all available real time data of the

solar panels, the battery and the charging

status. Once the sun icon is shown inside

the solar power gauge, the charger is active.

When the moon and stars icon is shown,

the charger is inactive due to a lack of solar

light.

To select a different TBS device (if

available), you can press the arrow button

on the upper left side of the screen to jump

back to the device list screen.

In the upper right corner of this screen

there are two buttons for respectively

entering the history graph screen or the

settings screen.

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The history graph screen shows you the

solar energy yield of the current day and

previous days. Additionally it also indicates

the minimum and maximum battery

voltages, maximum charge current and

charge power and total Amphours charged

of each day. You can swipe left to show

more days or rotate your device to enter

landscape view.

Please note that since the Omnicharge Solar

is not equipped with a real time clock, it

determines a day length based on solar

light input. So the best indications are

always given once the current day has

completely passed.

In the settings screen you have four

options.

The Status button will direct you to a status

overview screen showing device name,

firmware version, historic data etc.

The Setup button will direct you to the

Setup screen.

The Reset button allows you to either

perform a full factory reset, or to only clear

all history data.

And finally the About this App button,

which directs you to a screen with app

information, legal stuff and a link to our

website.

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3.2 Setting up the Omnicharge Solar charger

!

CAUTION

Invalid battery type or other parameter settings can cause serious damage to your

batteries and/or connected battery loads. Always consult your battery’s documentation

for the correct charge voltage settings.

As explained earlier, when you wish to setup the charger in a clearer way or wish to create a charge

program with different voltages or other parameters, the Dashboard Mobile app is the way to go.

If from the settings screen

you have pressed the

Setup button, the first

screen on the right will

appear. In this screen you

can select the desired

battery type by pressing

the upper button.

When you have selected

battery type Flooded,

AGM, Gel, Lithium 12V or

Lithium 24V and then

press the back button, all

corresponding settings

can be reviewed but not

edited. This is because

these are the factory

default battery types /

charge programs. For

most applications the

standard charge programs

will be sufficient.

When the desired battery

type has been selected,

please press the back

button and the app will

ask you to save this

setting or not. Press ‘Save’

and the charger will be

updated.

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If any of the standard selectable battery

types does not fulfil your requirements, there

is a possibility to create your own battery

type or charge program.

For this you need to select battery type

Custom Lead if you have a lead based battery

installed, or Custom Lithium if you have a

lithium based battery installed.

Once selected you will see that all available

parameters can now be edited. In the app

each parameter is explained with text below

the button. Please note that only for lead

based batteries you can set the Nominal

Battery Voltage to Auto. For Lithium based

batteries, you must select a nominal voltage

manually.

You will also notice that when Custom

Lithium is selected, there are a lot less

parameters to edit since a float stage and

equalization are not possible for Lithium, as

well as temperature compensation of the

charge voltage. When you do wish to have a

float stage for your lithium battery, please

see chapter 3.2.1.

When the desired custom battery type has

been edited, please press the back button

and the app will ask you to save these

settings or not. Press ‘Save’ and the charger

will be updated.

3.2.1 Creating a lithium charge program with a float stage

As explained above, as standard an Omnicharge Solar charger does not offer a float stage for lithium

batteries. If desired however, there is a way to still create a charge program with float for a lithium

battery.

For this please select the Custom Lead battery type in the setup screen and use the following

parameter settings:

• Battery Type → Custom Lead

• Nominal Battery Voltage → select a voltage manually, do not choose Auto

• Charge Voltage → Enter the desired charge voltage

• Absorption Time → Enter the desired absorption time

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• Float Voltage → Enter the desired float voltage

• Restart Voltage → Enter the desired restart voltage

• Auto Equalize Charge → Off

• Equalize Voltage → Enter the same value as Charge Voltage

• Equalize Duration → 10min (do not set to 0min.!)

• Temperature Compensation → Not Compensated

• Undervoltage Alarm On Value → Enter the desired voltage

• Undervoltage Alarm Off Value → Enter the desired voltage

• Undervoltage Alarm Delay Time → Enter the desired time

The parameters indicated in red are very important. Please use exactly these values for correct

functionality.

3.3 Overview of factory default charge program parameters

Please see the table below for an overview of the main factory default parameter values of each

battery type:

Battery type1)

Parameter

AGM (SLD)

GEL

Flooded (FLD)

Lithium /

LiFePo4 (LI)

Charge Voltage

14.6V

14.2V

14.4V

Absorption Time

120 minutes

-

Float Voltage

13.6V

13.4V

-

Restart Voltage

13.2V

Auto Equalize

Charge

-

30 days

-

Equalize Voltage

-

14.8V

-

Equalize Duration

-

120 minutes

-

Temperature

Compensation

-3mV/°C/cell

-

Overvoltage

Alarm

16.0V

Undervoltage

Alarm On Value

11.6V

12.0V

Undervoltage

Alarm Off Value

12.4V

Undervoltage

Alarm Delay Time

6 seconds

1) Multiply all voltage values by a factor of 2 for 24V systems

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4. TROUBLESHOOTING GUIDELINE

Please see the table below if you experience any problems with the Omnicharge Solar charger

and/or the installation.

Problem

Possible cause

Remedy

Omnicharge Solar charger is

not working at all (no LEDs).

Battery and/or solar panel

incorrectly connected

Please check if the polarities

of the battery or solar panel

connection are correct

Battery fuse blown or solar

panel switch turned off

Check any fuses and/or DC

switches in the battery and

solar panel wiring. Measure

the voltage at the battery

and solar inputs of the

charger for correct values.

Charger damaged

Please contact your TBS

dealer for further assistance

Charger seems to be

powered (battery indicator

LEDs are on) but does not

charge

No solar light

Please make sure that the

solar panels are not covered

and exposed to sufficient

sunlight.

Incorrectly connected solar

panel

Please check solar panel

wiring to the charger and

make sure that there are no

fuses blown or DC switches

opened and that the

polarity is correct.

Solar panel voltage too low

Make sure that the solar

panels are generating a

voltage that is at least 2V

higher than the current

battery voltage. Check input

terminals of the charger.

Solar panel voltage too high

Please check if the solar

panel is not exceeding the

maximum input voltage of

the charger. If it does,

disconnect immediately and

revise the installation.

Battery is full

If the battery is full the

charger will stop charging or

will greatly reduce the

charge current.

Incorrect battery settings

Check if the Nominal Battery

Voltage corresponds to the

actual used battery.

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Charge current is too low

Insufficient solar power

Make sure that the solar

panels are exposed to

sufficient sunlight. Check if

the solar panel array is sized

correctly in terms of power.

Charger operates too hot

When the charger is too hot,

the charge current will be

reduced automatically.

Please check the charger’s

mounting location and make

sure of sufficient cooling.

Batteries are not fully

charged

Battery load current is

higher than the charger’s

output current

If you wish to fully charge

the battery, please reduce

the DC loads connected to

the battery.

Incorrect battery settings

Check if the Charge Voltage

(bulk/absorption) is not set

too low for the used

battery.

DC cables too thin

Install larger DC cables. See

the DC cable size table in

chapter 2.3 of the

installation manual.

Insufficient solar power

Make sure that the solar

panels are exposed to

sufficient sunlight. Check if

the solar panel array is sized

correctly in terms of power.

Batteries are overcharged

Nominal Battery Voltage

setting too high

Check if the Nominal Battery

Voltage corresponds to the

actual used battery.

Battery Charge Voltage

setting too high

Please if all battery charge

voltages are set correctly

(Charge Voltage as well as

Float voltage if applicable)

Equalization issue

Please check if the

connected battery is

suitable for the equalization

stage. In general, only

Flooded (open lead)

batteries are allowed to be

equalized periodically.

Battery too old or damaged

Replace battery

Unable to connect using

Bluetooth

Charger not powered up

Please check if at least one

LED is lit on the charger

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Too large distance between

charger and mobile device

Make sure that you are in

the neighbourhood of the

charger. The maximum

theoretical distance for

Bluetooth is 15-20m. But in

practice due to surrounding

objects, this distance is

much smaller for correct

operation.

Bluetooth not allowed in

Dashboard Mobile app

Please make sure that you

have allowed Bluetooth

connections to be made by

Dashboard Mobile. If you

did not, please uninstall the

app and re-install it or

change this in the device’s

system settings afterwards.

Bluetooth not enabled on

mobile device

Please check the Bluetooth

settings of your device

If none of the above remedies will help solving the problem you encounter, it’s best to contact your

local TBS distributor for further help and/or possible repair of your Omnicharge Solar unit. Do not

disassemble the charger yourselves, it is not user serviceable and it will also void your warranty.

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