Flexcharge NC25A-12, NC25A-36, NC25A-48, NC25A-24 User Manual
MANUAL
MODEL: NC25A-12(24, 36, 48)
Ultra High Efficiency
25 Ampere Alternative Energy Battery
Charge Controller
For GEL, AGM, and Flooded Cell Lead Acid Batteries
Not for Lithium Batteries
SES Flexcharge USA, 1217 State St., Charlevoix, MI 49720
Ph: 231-547-9430, Web Site: www.flexcharge.com
12V Controller Shown Below
Patented
Rev 04, Ver1
AUG 2018
Page 1 of 24
IMPORTANT INFORMATION
Table Of Contents
Page
Contents
1
Cover
2
Table Of Contents
3
Features
4
Controls and Indicators
5
Installation Instructions
7
Indicator Functional Description
8
Flexcharge Energy State Charge Method (ESCM)
9
Operating Characteristics - Wire Selection Chart - Diode Selection Chart
10
Using or Not Using Blocking Diodes
11
Solar Panels Charging One Battery Bank
12
Solar Panels Charging Two Battery Banks
13
Wind/Water Generator Charging One Battery Bank
14
Wind/Water Generator Charging Two Battery Banks
15
Solar with Wind/Water Generator Charging One Battery Bank
16
Solar with Wind/Water Generator Charging Two Battery Banks
17
Charging Two Battery Banks Using a Selector Switch
18
Charging Two Battery Banks Using an A/B Battery Switch (Not Recommended)
19
Charging From Smaller Outboard Motors
20
Expanding the NC25A to Regulate High Ampere Charging Sources
21
Troubleshooting Guide
22
Charging Efficiency Graphs
23
General Guidelines for Designing Your System, and Warranty Information
THE NC25 CONTROLLER IS AN "ON/OFF" REGULATOR NOT A CONSTANT VOLTAGE
REGULATOR, AND THEREFORE IT CANNOT BE TESTED BY SIMPLY MEASURING THE OUTPUT
VOLTAGE ON THE TERMINAL STRIP OF THE CONTROLLER. THE CONTROLLER MUST BE
CONNECTED AS SHOWN IN ONE OF THE SCHEMATICS BEFORE IT WILL REGULATE.
READ ALL OF PAGES 5 through 8 OF THIS MANUAL TO LEARN HOW THE CONTROLLER
REGULATES BEFORE CONCLUDING THAT YOUR CONTROLLER IS NOT REGULATING.
All wire to wire and crimp connections must be
soldered for this, or any charge controller to
operate dependably.
Do not solder on the controllers terminal block.
The terminals on the controller are coated with an
anti corrosion coating.
Page 2 of 24
Features
Use Flooded Cell Battery settings for all AGM type batteries.
* 5 YEAR WARRANTY.
* COMPLETELY SEALED ELECTRONICS FOR MARINE OR OUTDOOR MOUNTING.
* LOW BATTERY VOLTAGE INDICATOR. (FLASHING RED LIGHT).
* Works with GEL, AGM, and Flooded Cell Lead Acid Batteries. Also for flooded Ni-Cad Batteries
* ARC REDUCTION CIRCUITRY TO ELIMINATE OR REDUCE RELAY CONTACT WEAR.
* CHARGING EFFICIENCY BETTER THAN 99.50% FROM 0.5A TO 30A OF CHARGING CURRENT.
* OPERATES EFFICIENTLY (98%) WITH AS LITTLE AS 0.1A OF SOLAR PANEL CHARGING
* EFFICIENTLY CHARGES BATTERIES FROM 0 VOLTS WITH FULL POWER.
* No RFI or EMI emissions to interfere with radio or data logging equipment
* 25 AMP CHARGE CAPACITY. SPECIAL ORDER 24V, 36V, AND 48V MODELS, OR EXPANDED
* 25 AMP CHARGE DIVERT CIRCUIT. STABLE DIVERT CIRCUITRY PREVENTS ERATIC RELAY
* DIVERTS ONLY WHEN VOLTAGE AND CURRENT ARE AT USABLE LEVELS.
PERFECT FOR MOTOR TYPE DIVERT LOADS (FANS, PUMPS, etc...)
* PEAK CHARGE VOLTAGE ADJUSTMENT WITH A RANGE OF 13.8V TO 15.9V (Multiply by 2,3,or 4
* CHARGES WITH THE SAME HIGH ACCURACY VOLTAGE SENSING THROUGH BATTERY
* CONSUMES LESS THAN 5mA (0.005A) WHILE CHARGING AND AT NIGHT, 2mA IF YOU DO NOT
* CHARGES BATTERIES AT FULL POWER, BELOW THE PLATE SATURATION POINT, THIS
* BATTERIES START CHARGING AT 0.005A OF CHARGE CURRENT.
* CONTROLLER CAN WITHSTAND OPEN CIRCUIT INPUT SPIKES OF 1500VA, & 140V CONTINOUS
* REVERSE POLARITY AND TRANSIENT VOLTAGE PROTECTION ON THE BATTERY SENSE WIRES.
* NO POWER WASTING SAMPLE PERIODS.
* REMOTE BATTERY VOLTAGE SENSING SO THE CONTROLLER CAN BE MOUNTED ANYWHERE
* EASY TO INSTALL USING THE LABELED CORROSION RESISTANT NICKEL / BRASS / STAINLESS
* U/L 94V-O RATED ENCLOSURE AND UL LISTED OR RECOGNIZED COMPONENTS.
CURRENT.
MODELS WITH CHARGING CURRENT CAPACITIES UP TO 2000A.
SWITCHING IF CHARGE SOURCE VOLTAGE DROPS.
to determine voltages for 24V, 36V, or 48V versions).
ISOLATORS.
USE THE CHARGE INDICATOR.
CHARGES BATTERIES FASTER, AND REDUCES ELECTROLYTE DEPLETION BY UP TO 90% OVER
CONVENTIONAL CONSTANT VOLTAGE, PWM, & HIGH FREQUENCY CHARGE REGULATORS.
WITHOUT DAMAGE.
BETWEEN THE CHARGING SOURCE AND THE BATTERIES.
STEEL CONNECTOR.
Page 3 of 24
Peak Charge Voltage Adjustment
Factory Calibrated for use with Lead
acid and Gel and AGM Battery
Technologies. Look for the small
calibration dent in the case
Do not move this adjustment unless
you have special battery voltage
requirements.
Multi Function Indicator
See the table on page 7 for
description of operation
Call Direct to the
Manufacturer. Technical
Questions, Warranty info, etc
231-547-9430
System Voltage
12= 12V, 24=24V,
36=36V, etc
Charging Input
Connect the
Positive Wire
from the
Charging Source
here.
Controller Output
to Battery
Connect to Fuse
then to Battery +
Divert Output
Connect to a Fuse
then to Divert Load
Positive (Optional)
Quick Reference
for custom
voltage settings.
(Optional)
General
Specifications
CONNECT
DIRECTLY TO
THE BATTERY’S
NEGATIVE (-)
TERMINAL
See Installation
Drawings.
Using the charge
Indicator is
optional
CONNECT
DIRECTLY TO A
FUSE THEN TO
THE BATTERY’S
POSITIVE (+)
TERMINAL
231
Page 4 of 24
INSTALLATION INSTRUCTIONS
Flexcharge
TM
USA NC25A
ULTRA HIGH EFFICIENCY CHARGE CONTROLLER
Congratulations, you will soon be using the most efficient controller available. Using this
controller has the direct equivalency of increasing your solar panel capacity by up to 20% over
any other controller FlexchargeTM USA has examined. This controller is available with
capacities to 2000 amps with the same, or increased charging efficiencies.
NOTE: The NC25A does not contain any blocking diodes.
IMPORTANT: PLEASE READ THE SECTION "USING BLOCKING DIODES" Pg.10
Do not wire your solar panels in series for higher voltage output. Use the following voltages for best
performance. 12 volt systems. V peak power 15 VDC, 24 volt systems V peak power 30 VDC, 36 V
systems V peak power 45 VDC, 48 V systems 60 VDC. You can be up to 5 volts higher with no affect
but not lower. For example using a 100 watt panel with a peak power voltage of 30 volts on a 12 volt
system will only give you a charge rate of about 50 watts while a peak power voltage of 15 volts would
give you the full 100 watts.
1) Choose a good mounting location.
Even though the controller has been designed for mounting outside, mounting it in a more protected
environment will help to extend it's operational life.
2) Install the NEGATIVE BATTERY SENSE WIRE from the controller's terminal block to the
battery bank negative (-) terminal. You should use #16 to #14 awg black wire.
3) Install the POSITIVE BATTERY SENSE WIRE from the controller's terminal block to a 1A or 2A
fuse and then to the battery bank's positive (+) terminal. You should use #16 to #14 awg
yellow or red wire.
IMPROTANT
When installing the terminals on to the sense wires for connection to the battery, crimp then
solder the terminals to the wire. Make absolutely sure these wires make very good electrical and
mechanical connection with the battery's terminals. If either of this or the ground connections were to
loosen, or corrode, the controller will have no way to sense battery voltage, causing it to switch to a
non-regulating mode and overcharge the batteries. The sense wires may be extended up to 100 feet
using #14 or larger wire. All splice joints must be soldered. If you are charging multiple isolated battery
banks through a battery isolator, connect the SENSE wires to the primary (most used) battery bank.
The other batteries will follow the primary battery's voltage, and will not be over or under charged.
IMPORTANT
For the next four steps, see the Wire Size Table on page 9 to select the correct size wire for your
charging current and length of wire.
4) Connect the charging source negative (-) wire to the negative (-) terminal on the battery
and/or the system's negative battery bus. If you are using a smart battery fuel meter that
measurers total Input to Output Amp/Hours, it will usually have a shunt in the (-) connection to the
battery. Connect the (-) wire from the charging source to the shunt as shown in the meter’s manual.
5) Install the BATTERY POSITIVE (BAT. +) wire from the controller to the battery's positive
terminal. A fuse rated at 1.5 times larger than your maximum charging current, but less than
30A, should be installed in this wire near the battery. Remember to solder all wire connectors
even if they use crimped connectors.
Page 5 of 24
6) Connect the charging source (Solar, Wind, etc.) positive wire to the controller's INPUT+
terminal. CAUTION: IF THE SOLAR PANELS ARE EXPOSED TO LIGHT, THEY WILL BE
GENERATING POWER. WIND SYSTEMS SPINNING UNCONNECTED CAN HAVE VOLTAGES
ABOVE 100V. It is preferred to stop the generator from turning before connecting the wires from it.
There will be a spark when you attach this wire if the charging source is generating power, this may
be OK if it is not turning very fast but be sure you are not near any flammable fumes. Turn off the
source if possible.
7) DIVERT Feature. When installing a Divert Load, the following steps must also be followed.
You must use a properly sized Divert Load on wind and towed generator systems
a) Connect the Divert Load's negative (-) wire to the negative (-) terminal on the battery or the
system's negative battery bus. If you are using a smart battery fuel meter that measurers total
Input to Output Amp/Hours, it will usually have a shunt in the (-) connection to the battery. Connect
the (-) wire from the Divert Load to the battery (-) not to the shunt as shown in the meter’s manual.
b) Install a fuse rated at 1.5 times larger than your maximum charging current, but less than
30A, in the Divert wire near the controller's terminal block in the Divert Load's positive wire.
Choosing the right Divert Load
The Divert output from the controller is unregulated. This means that when the controller is in Divert
mode, this terminal is directly connected to the charging source, just as if there were no controller
installed. (i.e. The solar panels connected directly to the Divert Load) If the divert load draws less
current than the maximum charging current of your system, the load could burn up. The best rule of
thumb is; either use a Divert Load with a voltage rating twice that of your battery system, or one that
has the same voltage rating as the batteries but has a current rating equal to the maximum your system
can generate. See the Flexcharge Divert loads at www.flexcharge.com
8) CHARGE INDICATOR LIGHT. It is not necessary to use the Charge Indicator Light. If you wish
to use it, connect the CHARGE INDICATOR TERMINAL on the controller's terminal block, to one of
the charging source’s diodes, at the source end. For example; on a solar panel it would connect to
the solar panel end of the diode. See the wiring diagrams. In order to maintain the ultra high
charging efficiencies in the NC25A, it may not be feasible to use the charge indicator while charging
from outboard motors or on certain wind generators. If you have access to the blocking diode in the
charging source or you are charging through a dual battery isolator, then you can use the charge
indicator. A much more informative indication of charging is an amp meter installed into the Red
BAT+ wire anywhere between the controller and the battery.
This concludes the installation section.
If the controller does not function as you think it should, first check the troubleshooting guide in this
manual, then call your dealer, or Flexcharge USA at (231) 547-9430. Web Site www.flexcharge.com
For an explanation of the multi function indicator operation, see the Indicator Function Table on page 7.
Setting the Peak Charge Adjustment Voltage to a new value
WARNING: Mis-adjustment of the controller could seriously damage your batteries over time.
NOTE: The PEAK CHARGE ADJUST was set at the factory to 2.375V per cell (14.25 volts for 12V
systems). All battery voltages are for batteries at 68 degrees F. Peak voltages should be set
higher for colder temperatures and lower for warmer temperatures. The Ideal voltage setting for
Wet Cell Lead Acid and AGM Batteries is 2.39V per cell, (14.35V for 12V systems). The Ideal setting
for Sealed Gel batteries is 2.35V per cell (14.15V for 12V systems). The 2.375V per cell position was
marked with a small indent in-line with the slot in the adjuster. The 2.37V per cell voltage setting works
well with Wet Cell Lead Acid, AGM and Gel battery Technologies. If you move the adjustment and
want to put it back near the original setting, line up the slot as closely as possible with the small indent
(dot) in the case. You should recalibrate the controller if the adjustment is moved.
1) Setting a new regulated voltage, or checking the regulation voltage of your controller.
Page 6 of 24
NOTE: THE BATTERY BANK MUST BE FULLY CHARGED TO PERFORM THIS TEST, AND THE DIVERT
Indicator Function Description
Charge Indicator Not Used
Charge Indicator Used
Charging
(Battery Voltage Is Above 11V)
none
STEADY Green
Charging
(Battery Voltage Is Below 11V)
FLASHING Red
FLASHING- Green to Orange
Not Charging
(Battery Voltage Is Below 11V)
RAPID FLASHING Red
RAPID FLASHING Red
Charge Divert
STEADY Red
STEADY Orange
Not Charging
(Charging Source is NOT Making Power &
Battery is Above 11V)
none
none
LIGHT MUST BE OFF LONGER THAN 10 SECONDS AT A TIME. IF THE DIVERT LIGHT IS NOT OFF LESS
THAN 10 SECONDS, COVER SOME OF THE SOLAR PANEL(S) WITH A BLANKET OR CARDBOARD TO
SLOW THE CHARGE RATE. All Flexcharge controllers are 100% tested and calibrated at the factory.
a) Connect an accurate digital voltmeter on the terminals of the battery you are charging.
b) If you are only checking the unit, skip this step, and step "d". Turn the adjustment most of the
way towards "+". The dot in the case near the adjustment is the factory setting of 2.375V per cell.
Continued…
c) Watch the voltmeter for the highest voltage you wish the batteries to charge to.
d) SLOWLY turn the adjustment towards "- " until the DIVERT indicator comes ON (steady red
or orange).
e) Allow the controller to cycle a few times while watching the voltmeter, and fine tuning the
adjustment for the exact upper switch voltage you desire. Remember the controller will
switch ON and OFF (Charge to Divert then back to Charge) while you are performing this test,
and if it is switching too fast your voltmeter readings will be inaccurate which could cause
you to set the controller at the wrong voltage.
Easier Calibration Method
Note: The peak voltage setting on the NC25A is set to 2.375V per cell (14.25V for 12V systems only) at
the factory. This voltage setting is ideal for sealed gel batteries that recommend a 14.10V constant
voltage setting (see the charge process graph). The factory setting will also work with vented lead acid
and AGM batteries, however setting the peak voltage at 14.35V will give the batteries a more active
charge. You may use the method described in step 6, or an easier way may be to start your engine,
and allow the engine alternator to charge your batteries up to about 14.4 volts. Then simply turn the
adjustment on the NC25A towards "+" until the DIVERT light turns OFF then slowly turn it back until the
DIVERT light comes ON. The NC25 will now regulate the battery voltage at the same voltage as your
engine alternator, which is usually about 14.4V
Coat the battery's terminals with battery terminal grease to prevent future problems caused by
corrosion.
NC25A controllers are available for 12, 24, 36, 48 volt systems with charging capacities of, 60 & 100
amperes. Special order units with 60 ampere up to 2000 ampere charging capacities.
For more information call your dealer or FlexchargeTM USA at 231-547-9430
Visit our Web Site: www.flexcharge.com
Description of Multi Function Indicator Operation
Page 7 of 24
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