Trace Engineering C35 - REV B, C40 - REV B, C60 - REV B, C Series, C35 User Manual

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C-Series

Multifunction DC Controllers

Installation and Operation Guide

P/N 975-0004-01-01 Rev. B 11/00

C-Series

Multifunction DC Controllers

Table of Contents

Section Description Page

1. INTRODUCTION ............................................................. 1

2. FEATURES ..................................................................... 5

3. INSTALLATION............................................................... 10

Operating Modes

Photovoltaic Charge Control Mode Automatic PV Array Night Disconnect Diversion Control Mode DC Load Control Mode

Over-Temperature Protection Electronic Over-Current Protection Battery Temperature Compensation LED Status Indicator Charge or Diversion Control Mode Indications

Solid Green Blinking Green

Load Control Indications

Solid Red Blinking Red Slowing Blinking Orange

Equalization Mode Indication

Alternating Red and Green

Error Mode Indication

Fast Blinking Orange

Mounting Wiring

Minimum Recommended Wire Size

Maximum One-way Distance and Wire Size PV Charge Control Mode Cabling Diversion Control Mode Cabling DC Load Control Mode Cabling Grounding Configuring the C-Series Automatic/Manual Battery Equalization and

Low Voltage Reconnect Operating Mode Reset Switch Voltage

Table of Contents (Continued)

Section Description Page

3. INSTALLATION (continued)

4. OPTIONS ........................................................................ 35

5. OPERATION ................................................................... 38

6. BATTERIES .................................................................... 41

Adjusting the C-Series Setting Voltage Parameters Testpoints for Voltage Settings Equalization Manual Equalization Automatic Equalization Temperature Compensation Setting LVR and LVD (Load Control Mode) Setting Diversion Control Mode

C-Series LCD Meter Displays Installing the DVM/C40 Mounting the CM/R

Three-Stage Battery Charging

Bulk

Absorption

Float Equalization

Automotive Batteries Maintenance-Free Batteries Deep-Cycle Batteries Sealed Batteries NiCad and NiFe Batteries Battery Sizing

8. DIVERSION LOADS ....................................................... 43

9. SPECIFICATIONS .......................................................... 46

10. SERVICE INFORMATION .............................................. 47

11. WARRANTY .................................................................... 48

Charge Controller Load Controller Diversion Charge Controller Diversion Load Types

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety instructions that should be

followed during the installation and maintenance of this product.

To reduce the risk of electrical shock, and to ensure the safe installation and operation of this product, the following safety symbols have been placed throughout this manual to indicate dangerous conditions and important safety instructions.

WARNING - A dangerous voltage or condition exists in this area.

Use extreme caution when performing these tasks.

AVERTISSEMENT - Une tension ou condition dangereuse

existe dans cette zone. Faire preuve dextrême prudence lors de la réalisation de ces tâches.

CAUTION - This procedure is critical to the safe installation or

operation of the unit. Follow these instructions closely.

ATTENTION - Cette procédure est essentielle à linstallation ou

lutilisation de lunité en toute sécurité. Suivre ces instructions de près.

NOTE - This statement is important. Follow instructions closely. NOTE - Cette déclaration est importante. Suivre les instructions

deprès.

· All electrical work must be done in accordance with local, national, and/or

international electrical codes.

· Before installing or using this device, read all instructions and cautionary

markings located in (or on) the manual, the inverter, the controller, the batteries, and the PV array.

· Do not expose this unit to rain, snow or liquids of any type. This product is

designed only for indoor mounting.

· To reduce the chance of short-circuits when installing or working with the

inverter, the controller, the batteries, or the PV array, use insulated tools.

· Remove all jewelry such as rings, bracelets, necklaces, etc., while

installing this system. This will greatly reduce the chance of accidental exposure to live circuits.

· The controller contains more than one live circuit (batteries and PV array).

Power may be present at more than one source.

· This product contains no user serviceable parts. Do not attempt to repair

this unit unless fully qualified.

SAVE THESE INSTRUCTIONS !

BATTERY SAFETY INFORMATION

· Always wear eye protection, such as safety glasses, when working with

batteries.

· Remove all loose jewelry before working with batteries.

· Never work alone. Have someone assist you with the installation or be

close enough to come to your aid when working with batteries.

· Always use proper lifting techniques when handling batteries.

· Always use identical types of batteries.

· Never install old or untested batteries. Check each batterys date code or

label to ensure age and type.

· Batteries are temperature sensitive. For optimum performance, they

should be installed in a stable temperature environment.

· Batteries should be installed in a well vented area to prevent the possible

buildup of explosive gasses. If the batteries are installed inside an

enclosure, vent its highest point to the outdoors.

· When installing batteries, allow at least 1 inch of air space between

batteries to promote cooling and ventilation.

· NEVER smoke in the vicinity of a battery or generator.

· Always connect the batteries first, then connect the cables to the inverter

or controller. This will greatly reduce the chance of spark in the vicinity of

the batteries.

· Use insulated tools when working with batteries.

· When connecting batteries, always verify proper voltage and polarity.

· Do not short-circuit battery cables. Fire or explosion can occur.

· In the event of exposure to battery electrolyte, wash the area with soap

and water. If acid enters the eyes, flood them with running cold water for

at least 15 minutes and get immediate medical attention.

· Always recycle old batteries. Contact your local recycling center for proper

disposal information.

1.0 INTRODUCTION

Introduction

The C35/C40/C60 (C-Series) controllers are among the finest controllers available and can be used with 12, 24, or 48 volt DC systems (depending upon model) as PV charge controllers, DC diversion controllers, or DC load controllers (low voltage disconnect). These capabilities make the C-Series the only DC controllers youll need! Numerous standard features are provided to maximize the performance of the system:

· Solid-state Pulse Width Modulated (PWM) charging process with three-

stage control, temperature compensation, and manual or automatic

equalization to maximizes system performance and increase battery life.

· Meets National Electrical Code (NEC) and other international controller

specifications.

· UL listed for the U.S. (UL Standard 1741 (draft) 1998), and Canada

(CSA-C22.2 No. 107.1-95).

· Electronic overload and short circuit protection with automatic and manual

reset capability increases the reliability of unattended systems by eliminating

blown fuses and tripped circuit breakers.

· Field adjustment of charge setpoints is provided by rotary controls with

removable knobs, reducing the potential for setpoint tampering. Calibrated

scales and test points allow precise adjustments of settings.

· Optional external battery temperature compensation sensor (BTS) for

automatic adjustment of charge setpoints (required by UL draft standard

1741 and strongly recommended for sealed batteries).

· Over-temperature protection for the electronic circuitry when used in hot

environments (over 113 °F/45 °C).

· Indoor-type, powder-coated enclosure for wall mounting.

· Multicolor LED with easy to read mode/status label.

· Optional LCD meter for remote or direct mounting on the controller. May be

mounted up to 1000 feet away.

· 2-year limited warranty.

1.0 INTRODUCTION

Operating Modes

The C-Series controller can operate as either a photovoltaic charge controller, a diversion controller, or a DC load controller. The controller cannot operate in more than one mode at the same time. If several modes are required in a system, a dedicated controller must be used for each mode.

Photovoltaic Charge Control

When this mode is selected, the status LED will indicate either blinking green or solid green. It will alternate red/green when in equalization mode.

Diversion Control Mode

When this mode is selected, the status LED will indicate either blinking green or solid green.

DC Load Control Mode

When this mode is selected, the status LED will typically indicate blinking red or solid red as the controller turns the DC loads OFF when battery voltage is low.

Photovoltaic Charge Control Mode

Depending on the model, the controller can regulate up to 60 amps of continuous photovoltaic (PV) array current at 12 or 24 volts (C60), or 12, 24 or 48volts DC (C40) for charging batteries. This rating includes the NEC required deratings. When used in this mode, ensure that the operating mode jumper is on the charge control pins. To enable the Photovoltaic Charge Control Mode, see Configuring the CSeries in the installation section of this manual.

If the PV arrays output increases above the rated amp level due to reflection or edge of cloud effect, the controller will continue to operate until the heatsink reaches a maximum safe operating temperature. This will take several minutes to occur depending upon the ambient temperature involved. When the heatsink reaches the maximum safe temperature, the controller will reduce the current, cooling the transistors and the heatsink.

If the current from the PV array reaches 85 amps, the controller will turn off to protect the circuitry. In the event of a shutdown, the controller automatically resets itself after 10 minutes (if overcurrent condition is no longer present).

The C-Series charge controller rapidly cycles the current source on-and-off to control the charging current and voltage of the battery. This occurs in both the charge control mode and the diversion control mode. The amount of time the current source is connected to the battery is varied to control the average current flow. This is often referred to as pulse width modulation (PWM) and allows the current to be tapered, rather than coarsely turning the current off and on as with relay type PV array charge controllers.

1.0 INTRODUCTION

Automatic PV Array Night Disconnect

At night, the PV array is automatically disconnected from the battery to prevent reverse leakage of power. This eliminates the need for a blocking diode between the battery and the PV array. If thin-film or amorphous solar modules are being used, diodes may still be required to prevent damage from partial shading conditions. Check the documentation provided with the PV modules.

Diversion Control Mode

The C-Series can operate as a diversion control to manage battery charging from alternative-energy sources such as wind or hydroelectric generators. Systems utilizing solar arrays do not have a requirement for diversion loads since a solar module can be open-circuited without damage. However, even with a solar based system it may be desirable to use excess power to operate DC loads. When used in this way, the C-Series controls a diversion load to redirect the excess power generated instead of allowing it to flow into the battery. This prevents damage to the charging source from an over-speed condition which could occur if the charging source is suddenly disconnected from all loads  as series relay regulators do. Consult your dealer for load and regulator size recommendations.

When the controller operates as a diversion regulator, it provides threestage regulation of battery voltage, with temperature compensation and automatic or manual equalization. See the Three-Stage Battery Charging section for more information on this process.

Diversion mode requires a separate dump load to regulate the battery. This load must be able to absorb more power than the charging source is able to produce at its peak output, or the DC voltage will become unregulated. The dump load must be available for the diversion of power at all times. Resistivetype heating elements are the best diversion loads. Special direct current water heating elements are available. Light bulbs and motors are not recommended as diversion loads because they are unreliable.

When used in diversion mode, ensure that the operating mode jumpers are on the charge control pins. See Configuring the CSeries in Section 3 of this manual.

Current draw of the diversion load is very important. Problems may arise from operating with a load that is too small or too large. A diversion load that is too small will not be able to absorb all the excess power from the current source once the batteries are full.

Diversion loads in excess of 85 amps are capable of absorbing more power than the C-Series is designed to handle, resulting in an over-current shut down. During this time, the unit will not regulate electrical flow in the system, and battery damage may result.

A diversion load that draws about 25% more current than the charging sources maximum output capability is usually suitable for use with the C-Series.

1.0 INTRODUCTION

DC Load Control Mode

The C-Series can also operate as a load control (also called a low voltage disconnect) to manage the discharging of the battery. A load controller prevents damage to the battery from over-discharge during periods of poor weather or excessive loads.

Battery

When used in load control mode, ensure that the operating mode jumpers are on the load control pins. See Configuring the C-Series section of this booklet.

The controller delays disconnecting the DC loads for 6 minutes after the voltage drops below the low voltage disconnect (LVD) setting. Loads are either automatically or manually reconnected when battery voltage exceeds the low-voltage reconnect (LVR) setting for 6 minutes. The EQUALIZE jumper determines manual or automatic reconnect when the C-Series is used as a load controller.

When used as a DC load controller, the settings of the LVR and LVD are controlled by two rotary potentiometers on the circuit board. The scale on the adjustment potentiometers differ from the scale used for other functions. A decal with the appropriate adjustment scale is included with the C-Series and shown below. Place this scale over the pots when using the C-Series as a load controller. Do not temperature-compensate these settings. Do not install the optional battery temperature compensation sensor.

Attach sticker over potentiometers for

Load Control Settings

C-Series

Controller

DC Load

Sticker Displaying Load Control Voltage Settings

Figure 1

2.0 FEATURES

Features

The C-Series features include over-temperature protection, electronic over-

current protection, and automatic battery temperature compensation.

Over-Temperature Protection

The temperature of the controllers transistors is continuously monitored. This protects the charge controller from damage in high temperature environments. If excessive temperatures are detected while operating in charge or diversion control mode, the controllers transistors are rapidly turned off and on to reduce the charge rate. This will reduce the transistor temperature.

As a load controller, the load is disconnected before the transistors reach an excessive temperature. Once the temperature has dropped, the loads are reconnected. When the over-temperature protection system has caused the controller to shutdown, the status LED will be orange and will blink fast (about once a second). This is the same indication shown during an over-current condition.

Electronic Over-Current Protection

During operation, the C-Series controllers continuously monitor the current flowing through it. If the current exceeds 85 amps, the transistor switches are opened, stopping the flow of electricity. The detection circuitry is faster than breakers or fuses, and they will not trip or blow when a fault occurs. When the over-current protection system is activated, the status LED will indicate orange and will blink fast (about once a second). This is the same indication as produced by an over temperature condition.

The C-Series controllers automatically resets the over-current protection system every 6 minutes. If an overload or short circuit is still present, the controller will shut off and wait another 6 minutes. This will occur continuously until the problem is corrected.

The reset switch on the right side of the controller allows the user to manually reconnect the PV array or DC loads after an over-current condition occurs. Hold the reset switch for 5 seconds to return to normal operation. If the controller is unable to restart, check the wiring and reduce the loads connected. There may be a delay after manually pressing the reset switch before reconnecting the PV array.

The shunt used to measure the current flow in the C-Series is located in the positive conductor of the circuit allowing greater flexibility in system grounding. The negative terminals are all common to one another.

2.0 FEATURES

Battery Temperature Compensation

The optional plug-in external Battery Temperature Sensor (BTS) automatically fine tunes the charging process of the C-Series. The BTS is required by UL Standard 1741 and UL approval is based on its installation. However, do not install the battery temperature sensor if you are using the C-Series as a DC load controller. The BTS may be extended by using a standard phone cable with RJ-11 plugs.

If the temperature sensor is installed, the regulation setpoints should be adjusted for a battery at room temperature (2327 °C/7480 °F). The C-Series adjusts the BULK and FLOAT setpoints 30 mV per degree Celsius for a lead-acid type battery and 20 mV per degree Celsius for a battery, as required per UL Standard 1741. For 24 and 48 volt systems, the compensation is twice and four times the values listed respectively. See Table 1.

If the temperature sensor is NOT installed, the setpoints should be adjusted for the temperature of the battery during operation. Seasonal adjustment of the setpoints may be necessary to prevent battery damage and to ensure proper charging. If the battery temperature sensor is installed, no seasonal adjustments are required (see Temperature Compensation in this manual).

If the wiring to the sensor is damaged and the wires are shorted or cut, the system will return to the non-temperature compensated settings.

Install the BTS on the side of the battery below the electrolyte level. It is best to place the sensor between batteries and place the batteries in an insulated box to reduce the influence of the ambient temperature outside the battery enclosure. Ventilate the battery box at the highest point to prevent hydrogen accumulation.

10-cell, NiCad type

6-cell,

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Charger Setpoint Temperature Compensation

Table 1

2.0 FEATURES

LED Status Indicator

A multi-color LED indicates the operating status of the controller. A colorcoded label is included on the cover of the controller explaining the status LEDs operation. When the controller is in Charge Control mode, the LED will be green. When in Load Control mode, the LED will be red. An orange LED indicates an error or a load disconnect condition. When battery equalization is in process, the LED alternates between red and green.

NOTE: The green and red color of the LED only indicates the particular operating mode and the battery voltage level. It does not indicate whether the charging source is functioning properly.

Multicolor LED Indicator

STATUS

C35 C40 C60

Green Blink Charge Control Mode Green Solid Battery Charged

Red Blink Load Control Mode Red Solid

Orange Blin k Slow Load Disconnected Orange Blink Fas t

Green

Red

35 Amp Controller 40 Amp Controller

60 Amp Controller

Alternating - Equalization Enabled

Batte ry Dis c h arg ed

Overload/Overtemp

12/24 VDC 12/24/48 VDC 12/24 VDC

Charge / Load Controller

5916-195th STREET NE ARLINGTON WASHINGTON 98223 TELEPHONE(360)435-8826 FAX(360)435-2229

CSeries Front Panel Label

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Battery Voltage LED Indications

Table 2

2.0 FEATURES

Charge Control or Diversion Control Mode Indications

Solid Green

The battery is being charged in the FLOAT stage. The status LED remains ON solid unless the batteries drop below the float voltage setting for an accumulative period of one hour. This allows the user to confirm that the system reached the float stage during the charging process when checked at the end of the day. Reaching the float stage frequently is a good indication of proper system operation and will maximize battery life and performance.

Blinking Green

The controller is in the CHARGE CONTROL or DIVERSION CONTROL mode and the battery is not fully charged. As the battery voltage approaches the BULK setting, the status LED will blink green several times (up to five) and then pause, indicating the battery voltage is approaching the bulk setting and provides an indication of the battery condition. Refer to Table 2 on the previous page to determine the battery voltage.

NOTE: A single green flash indicates the battery is below the bulk voltage setting. It does NOT indicate the batteries are charging.

Load Control Indications

Solid Red

The controller is in the DC LOAD CONTROL mode and the battery voltage has reached the Low Voltage Disconnect (LVD) setting. After a 6-minute delay, DC loads will be disconnected unless the user reduces the loads to a point that the battery voltage exceeds the LVD setting.

Blinking Red

As battery voltage approaches the LVD setting, the LED will blink red several times (up to five) and then pause providing an indication of battery voltage. Refer to Table 2 on the previous page to determine the battery voltage.

Slow Blinking Orange

The controller is in the DC LOAD CONTROL mode and has disconnected the loads due to reaching the LVD setting. The user can press the reset switch for a maximum 10-minute grace period, or can wait until the voltage rises above the Low Voltage Reconnect (LVR) setting to allow an automatic reset to occur.

2.0 FEATURES

Equalization Mode Indication

Alternating Red and Green

The controller is in the EQUALIZE mode. It will automatically stop the equalization process after accumulating two hours of operation at a voltage above the BULK setting. The user can stop the equalization process at any time

by pressing the reset switch until the status LED stops alternating red and green.

Error Mode Indication

Fast Blinking Orange

The controller detected an over-current or an over-temperature condition and the loads are disconnected. The controller will try to automatically restart the loads after a 6-minute delay. If the controller will not restart, turn off all loads and press the reset switch. If it then restarts, the loads may be too large. A delay up to five seconds may occur before the controller attempts to restart after pressing the reset switch.

3.0 INSTALLATION

Installation

The C-Series controllers are state-of-the-art precision electronic instruments. Installation, environment, mounting, and wiring must be accomplished in accordance with applicable local and national electrical codes. The instructions that follow are applicable to the typical installation. For special applications, consult a qualified electrician or your Trace dealer. Installation procedures will vary according to your specific application.

Mounting

The C-Series controllers are designed for indoor mounting. Care should be taken in selecting a location and when mounting the enclosure. Avoid mounting it in direct sunlight in order to reduce heating of the enclosure and subsequent high operating temperatures. The enclosure should be mounted vertically on awall.

Mounting and enclosure dimensions are shown in Figure 2 (the C-35 controller does not feature an external heat sink). Remove the faceplate on the controller and locate the upper two screw locations on the wall. The back of the enclosure is provided with keyholes for mounting. Leave the screw heads backed out approximately 1/4 inch (6 mm) or less. Place the controller onto the screws and pull it down into the keyhole slots. Then insert the two lower screws to lock the enclosure onto the wall. Provide either strain-relief clamps or conduit to prevent damage to the circuit board and terminal block from pulling on the wires. The cover should be replaced and retained with the screws provided (#10-32 x 3/8" SMS).

In outdoor installations, the C-Series units must be installed in a rainproof enclosure to eliminate exposure to rain or water-spray. The use of conformalcoated circuit boards, plated terminals, powder-coated metal components, and stainless steel fasteners improves tolerance to hostile environments.

CAUTION: INSTALL THE C-SERIES CONTROLLER IN A DRY, PROTECTED LOCATION AWAY FROM SOURCES OF HIGH TEMPERATURE, MOISTURE, AND VIBRATION. EXPOSURE TO SALTWATER IS PARTICULARLY DESTRUCTIVE. CORROSION OF THE CIRCUIT BOARD IS NOT COVERED BY THE WARRANTY.

3.0 INSTALLATION

Heatsink not included on C-35.

Figure 2

CSeries Dimensions

Do not locate the C-Series controller in a sealed compartment with the batteries. Batteries can vent hydrogen sulfide gas, which is corrosive to electronic equipment. Batteries also generate hydrogen and oxygen gas that can explode when exposed to a spark.

If using sealed batteries, the controller can be mounted in the same enclosure as long as it is adequately ventilated.

+ 39 hidden pages

Trace Engineering C35 - REV B, C40 - REV B, C60 - REV B, C Series, C35 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual