Windy Nation 40 MPPT User Manual
TrakMax 40 User Manual
Revision 1.0
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TrakMax 40
MPPT Solar Charge Controller
CHC-TRMX-40
User’s Manual
windynation
03/06/2013
TrakMax 40 User Manual
Revision 1.0
Table of Contents
1 Introduction .................................................................................................................................................................. 3
1.1 Limited Warranty ............................................................................................................................................... 3
1.2 Restrictions ........................................................................................................................................................ 3
1.3 Warranty Claims & Return Procedures .............................................................................................................. 3
1.4 Disclaimer .......................................................................................................................................................... 4
1.5 Limitation of Liability .......................................................................................................................................... 4
2 Product Overview ......................................................................................................................................................... 5
2.1 Features ............................................................................................................................................................ 5
2.2 Specifications .................................................................................................................................................... 5
2.2.1 Electrical Specifications ................................................................................................................................ 5
2.2.2 Physical Specifications .................................................................................................................................. 6
2.2.3 Regulatory Information .................................................................................................................................. 6
3 Installation .................................................................................................................................................................... 7
3.1 Electrostatic (ESD) Precautions ........................................................................................................................ 7
3.2 Mounting ............................................................................................................................................................ 7
3.3 Grounding .......................................................................................................................................................... 8
3.4 Connections ...................................................................................................................................................... 8
3.5 Overcurrent Protection .....................................................................................................................................10
3.6 Overvoltage – Reverse Polarity Protection .......................................................................................................10
3.7 Parallel Connection ..........................................................................................................................................10
3.8 Communication Port .........................................................................................................................................11
3.8.1 Remote: RJ11 ..............................................................................................................................................11
3.9 Battery Temperature Sensor (BTS) ..................................................................................................................11
3.9.1 Temperature Compensation.........................................................................................................................11
3.9.2 Wiring the Battery Temperature Sensor (BTS).............................................................................................12
4 Operation ....................................................................................................................................................................12
4.1 Maximum Power Point Tracking (MPPT) ..........................................................................................................12
4.1.1 How MPPT Works ........................................................................................................................................13
4.2 Charge Mode ....................................................................................................................................................13
4.2.1 Factory Default Settings ...............................................................................................................................13
4.2.2 Three Stage Charge .....................................................................................................................................14
4.2.3 Equalization..................................................................................................................................................14
4.3 DC Load Control ...............................................................................................................................................15
4.3.1 Auto Night Disconnect ..................................................................................................................................15
4.3.2 Low Voltage Disconnect ...............................................................................................................................15
4.3.3 Low Voltage Reconnect ...............................................................................................................................15
4.4 Battery Selection ..............................................................................................................................................15
4.4.1 Battery Type Selector Switch Settings .........................................................................................................15
5 LED Indicators ............................................................................................................................................................16
5.1 Charge Control .................................................................................................................................................17
5.2 LED Modes .......................................................................................................................................................17
5.2.1 Low Voltage Disconnect (LVD) ....................................................................................................................18
5.2.2 Over Voltage of Load ...................................................................................................................................18
5.2.3 Over Temperature ........................................................................................................................................18
5.2.4 Over Current of Load ...................................................................................................................................18
6 Troubleshooting And Support .....................................................................................................................................18
6.1 Care ..................................................................................................................................................................18
6.2 Troubleshooting ................................................................................................................................................18
6.3 Support .............................................................................................................................................................19
7 Batteries ......................................................................................................................................................................19
7.1 Battery Types ...................................................................................................................................................19
7.1.1 Automotive Batteries ....................................................................................................................................19
7.1.2 Maintenance-Free Batteries .........................................................................................................................19
7.1.3 Deep-Cycle Batteries ...................................................................................................................................19
7.1.4 Sealed Batteries ...........................................................................................................................................20
7.2 Battery Sizing ...................................................................................................................................................20
7.3 Equalization Charging ......................................................................................................................................20
7.3.1 Equalization Set Points (Non-Sealed Batteries Only) ...................................................................................20
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Revision 1.0
1 INTRODUCTION
Windy Nation Inc. (“Windy Nation”) is not assembling the wind unit, installing the solar system, or any other
product offered by Windy Nation. Windy Nation, and its directors, officers, and employees disclaim, and by
purchasing a Windy Nation wind or solar powered product you accept all liability and responsibility for
damage to property, injury, or death arising out of or related to the use or misuse of any product offered by
Windy Nation.
1.1 LIMITED WARRANTY
Windy Nation warrants that the MPPT Charge Controller (the “Product”), will be free from manufacturing
defects in materials and workmanship under normal authorized use consistent with product instructions for a
period of one (1) year from the date the original purchas er (“Customer”) receives the Product (the “Warranty
Period”). This warranty extends only to the original purchaser. The Customer’s sole and exclusive remedy
and the entire liability of Windy Nation, its suppliers and affiliates for breach of the warranty is, at Windy
Nation’s option, either (i) to replace the Product (or defective component part(s)) with a new or reconditioned
Product (or component part(s)); (ii) to repair the reported problem; or (iii) to refund the purchase price of the
Product. Repaired or replaced products are warranted for the rem aind er of the orig inal warr a nt y period on l y.
No employee, agent, dealer or other person is authorized to give any warranties on behalf of Windy Nation
not expressly set forth in this limited warranty.
1.2 RESTRICTIONS
No warranty will apply if the Product (i) has been altered or modified except by Windy Nation; (ii) has not
been installed, operated, repaired, or maintained in accordance with instructions supplied by Windy Nation;
(iii) has been subjected to abnormal physical, thermal or electrical stress, misuse, negligence, or accident. If
Windy Nation determines that the problem with the Product is not due to a manufacturing defect in Windy
Nation’s workmanship or materials, or otherwise does not qualify for warranty repair, then the Customer will
be responsible for the costs of all necessary repairs and expenses incurred by Windy Nation.
1.3 WARRANTY CLAIMS & RETURN PROCEDURES
To be eligible for service under this warranty, the Customer must submit a service request within the
Warranty Period by contacting Windy Nation in writing or via telephone and obt aining a Ret urned Materials
Authorization (“RMA”) number. This RMA must be obtained before returning any product under this warranty.
Notification must include a description of the alleged defect, the manner in which the Product was used, the
serial number, and the original purchase date in addition to the name, address, and telephone number of the
Customer. Within five (5) business days of the date of notification, Windy Nation will provide the Customer
with an RMA number and the location to which the Customer must return the defective Product. Any Product
returned for warranty service shall be shipped at the expense and risk of the Customer. The Customer must
return the entire Product kit (or, if authorized by Windy Nation, the defective component parts), within fifteen
(15) days after issuance of the RMA number. Windy Nation will be under no obligation to accept any returned
Product that does not have a valid RMA number. Customer’s failure to return the Product within fifteen (15)
days of its receipt of an RMA number may result in cancellation of the RMA. All parts that Windy Nation
replaces shall become Windy Nation’s property on the date Windy Nation ships the repaired Product or part
back to the Customer. Windy Nation will use all reasonable efforts within thirty (30) days of receipt of the
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defective Product to repair or replace such Product. If a warranty claim is invalid for any reason, the
Customer will be charged at Windy Nation’s then-current rates for services performed and will be charged for
all necessary repairs and expense incurred by Windy Nation. If Windy Nation determines that a warranty
claim is valid, it will ship the repaired or replaced Product to Customer at Windy Nation’s cost.
1.4 DISCLAIMER
EXCEPT FOR THE EXPRESS LIMITED WARRANTY SET FORTH IN THE PREVIOUS PARAGRAPH,
WINDY NATION DISCLAIMS ALL WARRANTIES, EXPRESS, IMPLIED AND STATUTORY INCLUDING,
WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE WITH RESPECT TO ANY PRODUCTS PROVIDED BY WINDY NATION. NO
ORAL OR WRITTEN INFORMATION OR ADVICE GIVEN BY WINDY NATION, ITS DEALERS,
DISTRIBUTORS, AGENTS OR EMPLOYEES SHALL IN ANY WAY INCREASE THE SCOPE OF THIS
WARRANTY. WINDY NATION DOES NOT WARRANT THAT THE QUALITY OR PERFORMANCE OF THE
PRODUCTS WILL MEET YOUR REQUIREMENTS OR THAT YOU WILL BE ABLE TO ACHIEVE ANY
PARTICULAR RESULTS FROM USE OR MODIFICATION OF THE PRODUCTS. Some jurisdictions do not
allow the limitation or exclusion of implied warranties or how long an implied warranty may last, so the above
limitations may not apply to you. In any such jurisdiction, the warranty shall be limited to the minimum
warranty and period required by law.
WINDY NATION EXPRESSLY DISCLAIMS ALL LIABILITY FOR BODILY INJURIES OR DEATH THAT MAY
OCCUR, DIRECTLY OR INDIRECTLY, BY USE OF THE PRODUCT BY ANY PERSON.
1.5 LIMITATION OF LIABILITY
UNDER NO CIRCUMSTANCES WILL WINDY NATION OR ITS AFFILIATES OR SUPPLIERS BE LIABLE
OR RESPONSIBLE FOR ANY LOSS OF USE, INTERRUPTION OF BUSINESS, LOST PROFITS, LOST
DATA, OR INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND
REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT, TORT (INCLUDING
NEGLIGENCE), STRICT LIABILITY OR OTHERWISE, EVEN IF WINDY NATION OR ITS AFFILIATE OR
SUPPLIER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so these
limitations may not apply to you. Neither Windy Nation nor its affiliates or suppliers will be held liable or
responsible for any damage or loss to any items or products connected to, powered by or otherwise attached
to the Product. The total cumulative liability to Customer, from all causes of action and all theories of liability,
will be limited to and will no t exceed t he purc has e pric e of the Produc t paid b y Cus tomer. This warranty gives
the Customer specific legal rights and the Customer may also have other legal rights that vary from state to
state.
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TrakMax 40 User Manual
Parameter
Value @25oC
Battery System Voltage
24 volt battery system
Max Battery Charging Current
40 Amp
Load Current
15 Amp
Photovoltaic Input Voltage Range
12-55VDC
30-55VDC (24 volt battery charging)
Max PV Open Circuit Array
Voltage
55VDC
Efficiency
97% min @ full current
Typical Idle Consumption
At idle < 10mA
Revision 1.0
2 PRODUCT OVERVIEW
The TrakMax solar charge controller is a 40 amp 12/24 Volt Maximum Power Point Tracking (MPPT)
photovoltaic (PV) battery charge controller. Through the use of MPPT technology, TrakMax can increase
charge current up to 30% or more compared to conventional solar charge controllers. TrakMax’s
sophisticated three stage charge control system can be configured to optimize charge parameters to precise
battery requirements. The unit is fully protected against voltage transients, over temperature, over current,
reverse battery, and reverse PV connections. An automatic current limit feature allows use of the full 40 amp
capability without worr ying abou t overl oad or unnecessary fuse blows from excessive current, voltage, or
amp-hour based load control.
Series pass Pulse Width Modulation (PWM) charge voltage control combined with a multistage charge
control algorithm leads to superior charging and enhanced battery performance. The filtered PWM power
control system uses highly efficient and reliable power MOSFET transistors. The MOSFET’s are turned on
and off at high frequency to precisely control the charge voltage and the MPPT function.
Fully automatic temperature compensation of charge voltage is available to further improve charge control
and battery performance. The optional battery temperature sensor (included) is built for long term reliability.
The sensor element is environmentally sealed and encapsulated into a lug, which adheres directly to the
battery. The TrakMax also includes an isolated RJ11 port for connection to a PC computer for data logging
and system monitoring.
For large system current applications (greater than 40 amps), multiple TrakMax units can be connected in
parallel.
2.1 FEATURES
DC Load Output Por t
Optional battery temperature sensor ensures precise battery charging
LED displays to indicate the status of charge
Lightning protect ion
Reverse current protection at night
Three-stage battery charging (bulk, absorption, and float) with optional temperature compensation
Automatic overload protection in both active and passive modes
Microprocessor controlled
Silent, pulse width modulated (PWM), high efficiency operation
Auto detects system voltage (12 or 24 volt) at start up
2.2 SPECIFICATIONS
2.2.1 Electrical Specifications
12 / 24 VDC
(1) 9-18VDC battery voltage = TrakMax auto-detects 12
volt battery system
(2) 18-36VDC battery volta ge = Trak Max auto-detects
12-30VDC (12 volt battery charging)
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Overload Protection (DC load)
2.0*Inom>5s
1.25*Inom temperature controlled
Bulk Charge (adjustable)
14.6V(default)
29.2V(default)
Floating Charge (adjustable)
13.4V(default)
26.8V(default)
Equalization Charge
14.0V(default)
28.0V(default)
Overcharge Disconnection
14.8V
29.6V
Overcharge Recovery
13.6V
27.2V
Over-discharge Disconnection
10.8 V (default)
21.6V(default)
Over-discharge Reconnection
12.3V
24.6V
Temperature Compensation
-13.2mV/oC
-26.4mV/oC
Lead Acid Battery Settings
Adjustable
NiCad Battery Settings
Adjustable
Load Control Mode
1. Low Voltage Reconnect (LVR)
2. Low Voltage Disconnect (LVD): Auto disconnect
Low Voltage Reconnect
12.0-14.0 VDC
24.0-28.0 VDC
Low Voltage Disconnect
10.5-12.5 VDC
21.0-25.0 VDC
Ambient Temperature
0 – 40oC (full load) 40 – 60oC (de-rating)
Altitude
Operating 5000 m, Non-Operating 16000 m
Enclosure Protection Class
IP21
Battery Temperature Sensor
(BTS)
Optional remote sensor increases charging precision
Terminal Size (fine/single wire)
Maximum 6 AWG
Parameter
Value
Dimension (H x W x D)
7.56” (192mm) x 5.51” (140mm) x 2.6” (66mm)
Unit Weight
3.1 lb. (1.4Kg)
Mounting
Vertical wall mount - indoor only
Cooling
Natural cooling
Operating Temperature
0oC to 40oC (40oC to 60oC de-rating)
Storage Temperature
-25oC to 70oC
Operating Humidity
20 to 80% relative humidity (non-condensing)
Non-Operating Humidity
Greater than 95% relative humidity
38.7oC max wet bulb temperature with no damage
Revision 1.0
1.5*Inom >20s
NOTE: The optional battery temperature sensor automatically adjusts the charging process of the controller
according to the type of battery selected by the user. With the battery temperature sensor installed, the
controller will increase or decrease the battery charging voltage depending on the temperature of the battery
to optimize the charge to the battery and to maintain battery performance.
2.2.2 Physical Specifications
2.2.3 Regulatory Information
The TrakMax has safety approvals as follows:
• UL 1741
• FCC Part 15B
• EN61000-6-3:2001
• EN61000-6-1:2001
• EN 60335-1
FCC Requirements:
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1)
This device may not cause harmful interference, and (2) this device must accept any interference received,
including interference that may cause undesired operation.
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