TrakMax 40 User Manual
Revision 1.0
windynation
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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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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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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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3 INSTALLATION
Insure all terminating connections are clean and tight to prevent arcing and overheating.
Do not connect to a PV array capable of producing greater than 40 amps of short circuit current @ 25°C.
Do not connect to a PV array with an open circuit voltage (VOC) greater than 55 VDC. For 12 volt battery
charging, the open circuit voltage of the PV array must be between 12-30VDC. For 24 volt battery
charging, the open circuit voltage of the PV array must be between 30-55VDC.
Important: Installations should meet all local codes and standards. Installations of this equipment should
only be performed by skilled personnel such as licensed electricians and Certified Renewable Energy (RE)
System Installers.
3.1 ELECTROSTATIC (ESD) PRECAUTIONS
All electronic circuits may be damaged by static electricity. To minimize the likelihood of electrostatic
damage, discharge yourself by touching an electrical ground (e.g.: copper pipe) prior to handling the unit and
avoid touching components on the circuit boards. The risk of electrostatic damage is highest when relative
humidity is below 40%.
3.2 MOUNTING
The mounting location is important to the performance and operating life of the controller. The environment
must be dry and protected from water. If required, the controller may be installed in a ventilated enclosure
with sufficient airflow. Never install the TrakMax MPPT in a sealed enclosure. The controller may be
mounted in an enclosure with sealed batt er ies, but never with vented/flooded batt er ies. Batt ery fumes from
vented batteries will corrode and destroy the TrakMax MPPT circuits.
1. Place the TrakMax on a vertical surface protected from direct sun, high temperatures, and water.
The TrakMax requires at least 6 in (150 mm) of clearance above and below and at least 1 in (25
mm) on each side for proper air flow as shown in figure 3-1 below.
Figure 3-1: Required mounting clearance for airflow.
2. Place a mark on the mounting surface at the top of each keyhole (two per unit).
3. Remove the controller and drill a 3/32 in (2.5 mm) hole at the drill mark.
4. Insert a #10 screw into the pilot holes. Do not tighten the screw completely.
5. Leave a 1/4 in (6 mm) gap between the mounting surface and screw head
6. Carefully align the keyholes on the TrakMax with the screw heads and slide the TrakMax down
over the keyhole.
7. Tighten the keyhole screws.
8. Add two additional screws in the lower rectangular mounting cutouts.
Warning: Explosion/Corrosion Hazar d
Do not mount on flammable surface material (e.g.: wooden wall).
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Wire Type
75°C Wire
90°C Wire
Copper
6 AWG (16 mm2)
8 AWG (10 mm2)
Aluminum
4 AWG (25 mm2)
6 AWG (16 mm2)
LOAD BATTERY PV
- + - + - +
Revision 1.0
3.3 GROUNDING
The TrakMax is designed to work with grounded electrical systems. In the controller, ground is not connected
to the input terminal and output terminals.
Use a copper wire to connect the grounding terminal on the TrakMax enclosure to earth ground. The
grounding terminal is located on the lower right corner of the enclosure.
Do not connect the system negative conductor to this terminal. NEC requires the use of an external ground
fault protection device (GFPD). The system electrical negative should be bonded through a GFPD to earth
ground at one (and only one) location. The grounding point may be located in the solar circuit or the battery
circuit.
3.4 CONNECTIONS
WARNING: Shock Hazard
Solar PV array can produce open-circuit voltages in excess of 100 VDC when in sunlight. Verify that the
solar input breaker or disconnect has been opened (disconnected) before installing the system wires. Note
that the maximum PV open-circuit voltage for the TrakMax is 55 VDC. Do NOT attach the positive and
negative PV cables to the TrakMax until the TrakMax has been connected to the positive and negative
terminals of the 12 or 24 volt battery bank.
It is recommended to use a strain relief (bushings, connectors, clamp connectors, or wire glands ) in each of
the three ½ in openings.
The NEC requires that the wires carrying the system current never exceed 80% of the conductor’s current
rating. The table below provides the minimum size of copper wire allowed by NEC. Wire types rated for 75°C
and 90°C are included.
1) Remove the Wiring Cover from the Top Cover by removing the two securing screws as shown below.
2) Route the relevant cable/wire through the appropriate ½ in opening as noted on the cover.
Note: If strain reliefs (i.e.: cable clamps, wire glands) are being used, they must be installed prior to
routing the wire, and the wire should route through the clamp.
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Insert Wire/Cable Here
Tighten Terminals Here
Revision 1.0
3) Terminal connectors for DC wiring are located on the lower edge of the circuit board. Once the
wires have been installed, tighten the terminals with the screw located on the top of the terminals to
1.2Nm (10.6lb-in). Be careful not to over tighten.
a) Load: Maximum 15A DC Load
• Connect a cable from the TrakMax terminal marked load negative (–) to the negative terminal of your
DC load and tighten the screw.
• Connect a cable from the TrakMax terminal marked load positive (+) to the positive terminal of your
DC load and tighten the screw.
b) Battery: 40A Rated Charge Current
• Connect a cable from the TrakMax terminal marked battery negative (–) to the negative (–) battery
terminal and tighten the screw.
• Connect a cable from the TrakMax terminal marked battery positive (+) on the Solar charge
controller to the positive (+) battery terminal and tighten the screw.
c) PV: Photovoltaic System
• Connect the PV array’s positive (+) output to the terminal marked PV positive (+) on the TrakMax
and tighten the screw.
• Connect the PV array’s negative (–) output to the terminal marked PV negative (–) on the TrakMax
and tighten the screw.
4) Double Check All Connections to ensure they are secure.
5) Replace the Wiring Cover removed in step 1 and secure with the two screws.
6) Tighten the cable clamps (if applicable)
CAUTION: Risk of Fire and Shock
Connect battery terminals prior to the connection of array terminals.
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System Voltage
PV Over Voltage Point
Revision 1.0
3.5 OVERCURRENT PROTECTION
Circuit breakers or fuses must be installed in both the battery and solar circuits. The protection device ratings
and installation methods must conform to NEC requirements.
The battery circuit fuses or circuit breaker must be rated to 125% of the maximum current or more. The
minimum fuse/breaker rating allowed for use with each TrakMax is 1.25 x 40 Amps = 50 Amps.
If the TrakMax controller system detects an overload status, it will automatically reset the over current
protection system every 6 minutes. If the fault is still present, the controller will shut off and wait for another 6
minutes. This will occur continuously until the problem is corrected.
A disconnect is required for the battery and solar circuits to provide a means for removing power from the
TrakMax. Double pole switches or breakers are convenient for disconnecting both solar and battery
conductors simultaneously.
3.6 OVERVOLTAGE – REVERSE POLARITY PROTECTION
TrakMax is fully protected against reverse polarity and high voltage transients for both the PV and the battery
connections. If the battery is connected in the reverse polarity position, the TrakMax inner fuse will open. If
the PV array is connected in the reverse polarity position, the TrakMax will not turn on.
12V Battery 30VDC
24V Battery 55VDC
3.7 PARALLEL CONNECTION
Multiple TrakMax controllers can be installed in parallel on the same battery bank to achieve higher charging
current. For example, connecting two TrakMax units in parallel can allow for 80 amps of charging current,
and connecting three TrakMax units in parallel can allow for up to 120 amps of charging current. Additional
parallel controllers can also be added in the future. Each TrakMax MPPT Controller must have its own PV
array. See figure 3.5
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Figure 3.5: Parallel Connection
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Temperature
12 Volt Units
24 Volt Units
Celsius
Fahrenheit
Lead Acid
(6 cells)
NiCad
(10 cells)
Lead Acid
(12 cells)
NiCad
(20 cells)
55
131
-0.9
-0.6
-1.8
-1.2
45
113
-0.6
-0.4
-1.2
-0.8
40
104
-0.45
-0.3
-0.9
-0.6
30
86
-0.15
-0.1
-0.3
-0.2
Revision 1.0
3.8 COMMUNICATION PORT
Network connections allow the TrakMax to communicate with other controllers or com puters .
3.8.1 Remote: RJ11
Use standard 4-wire or 6-wire RJ-11 telephone cables (straight-through, not a Null Modem / cross-over). If
possible, pull the telephone cable through conduit before crimping on the RJ-11 connectors. If using preassembled cables, take care not to damage the plugs when the cables are pulled through conduit.
WARNING: Shock Hazard
Never route network cables in the same conduit as the power conductors.
3.9 BATTERY TEMPERATURE SENSOR (BTS)
The charge voltage required by batteries changes with battery temperature. Temperature compensation of
the charge voltage enhances battery performance and life, and decreases battery maintenance. Automatic
temperature compensation can be provided through use of the optional battery temperature sensor
(included). Table 3.9 describes approximately how much the voltage may vary depending on the temperature
of the batteries.
3.9.1 Temperature Compensation
60 140 -1.05 -0.7 -2.1 -1.4
50 122 -0.75 -0.5 -1.5 -1
35 95 -0.3 -0.2 -0.6 -0.4
25 77 0 0 0 0
20 68 0.15 0.1 0.3 0.2
15 59 0.3 0.2 0.6 0.4
10 50 0.45 0.3 0.9 0.6
5 41 0.6 0.4 1.2 0.8
0 32 0.75 0.5 1.5 1
-5 23 0.9 0.6 1.8 1.2
-10 14 1.05 0.7 2.1 1.4
-15 5 1.2 0.8 2.4 1.6
-20 -4 1.35 0.9 2.7 1.8
-25 -13 1.5 1 3 2
-30 -22 1.65 1.1 3.3 2.2
-35 -31 1.8 1.2 3.6 2.4
-40 -40 1.95 1.3 3.9 2.6
Table 3.9: Variances in charging voltage based on battery temperature
Temperature compensation is based on battery type-5mv /cell for lead acid type batteries and 2mv/cell for
alkaline type batteries (NiCad or NiFe). The temperature compensation calculations are derived from the
following tab le:
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Battery Type
12 Volt Units
24 Volt Units
Revision 1.0
Lead Acid 0.03 vo lts (30mv) per degree Celsius 0.06 volts (60mv) per degree Celsius
NiCad 0.02 volts (20mv) per degree Celsius 0.04 volts (40mv) per degree Celsius
3.9.2 Wiring the Battery Temperature Sensor (BTS)
1) Plug the provided RJ11 cable into the RJ11 socket labeled “BTS” located on the side of the TrakMax
as shown below.
2) Secure the BTS on the side of the battery below the electrolyte level as shown below. 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.
CAUTION: High power electrical systems pose dangers and it is the user's responsibility to be familiar with
these dangers and take any necessary action to ensure safe use. Shorting a battery or connecting your
controller to a battery can supply huge currents and have serious consequences including explosions,
causing fire, damage to equipment, and personal injury.
4 OPERATION
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4.1 MAXIMUM POWER POINT TRACKING (MPPT)
Maximum Power Point Tracking, frequently referred to as MPPT, is an electronic system that operates the
Photovoltaic (PV) modules in a manner that allows the PV modules to produce all the power they are
capable of producing.
MPPT and associated current boost operation is fully automatic and will function whenever sufficient PV
voltage and current are available. The percent increase in output charge current relative to PV current is
variable, and will change with operating conditions. When conditions are such that insuff ic ient PV power is
available to produce an increase in output current, the unit will stop its internal DC-DC power conversion and
operate as a series pass PWM controller with very low forward voltage drop.
The principal operating conditions which affect current boost performance are PV array temperature and
battery voltage. At constant solar intensity, available PV power changes with PV temperature. A PV array’s
power vs. temperature characteristic is such that a cool PV array can produce a higher voltage and more
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Charge Mode
Three (3) Stage
Absorption Voltage
14.4V
28.8V
Bulk Voltage
14.6V
29.2V
Float Voltage
13.4V
26.8V
Equalize
14V
28V
Revision 1.0
power, than a hot PV array. When PV voltage is sufficiently high for MPPT to operate, a constant power
output is delivered to the battery. Since output power is constant while MPPT is operating, a decrease in
battery voltage produces corresponding increase in charge current. This means that the greatest current
increase occurs with a combination of cool ambient temperature and low battery voltage. The unit delivers
the greatest charge current increase when you need it most, in cold weather with a discharged battery.
Additionally, anything that can be done to lower PV array temperature will also lead to increased charge
current by increasing PV power production. In cool/comfortable temperatures and typical battery states of
charge, most systems see about 10 – 20% increas e. C harge c urr ent inc reas e ca n go to zero in hot
temperatures, whereas charge current increas e can ea s il y exceed 30% wit h a dischar ge d battery and
freezing temperatures.
Figure 4.1: Current / Power vs. Voltage Characteristics
4.1.1 How MPPT Works
A PV module is a constant current type device. As shown on a typical PV module voltage vs. current curve,
current remains relatively constant over a wide range of voltage. A typical 75 watt module is specified to
deliver 4.45 amps @ 17 volts @ 25 C cell temperature. Conventional PV controllers essentially connect the
PV array directly to the battery when the battery is discharged. When a 75 watt PV module is connected
directly to a battery charging at 12 volts, the PV module still provides approximately the same current. But,
because output voltage is now at 12 volts rather than 17 volts, t he PV module’s power production is
artificially limited and the 75W PV module only delivers 53 watts. This wastes 22 watts of available power.
TrakMax’s MPPT technology operates in a very different fashion. Under these conditions TrakMax calculates
the maximum power voltage (V) at which the PV module delivers maximum power, in this case 17 volts. It
then operates the PV module at 17 volts which extracts maximum available power from the PV module.
TrakMax continually recalculates the maximum power voltage as operating conditions change. Input power
from the maximum power tracking controller, in this case 75 watts, feeds a switching type power converter
which reduces the 17 volt input to battery voltage at the output. The full 75 watts which is now being
delivered at 12 volts would produce a current of 6.25 amps. A charge current increase of 1.8 amps or 40% is
achieved by converting the 22 watts that would have been wasted into useable charge current. Note that this
example assumes 100% efficiency to illustrate the principal of operation. In actual operation, the power boost
will be somewhat less.
4.2 CHARGE MODE
4.2.1 Factory Default Settings
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4.2.2 Three Stage Charge
The TrakMax is configured for a three stage charging process, Bulk, Absorption and Float. The three stage
charge process provides a somewhat higher charge voltage to charge the battery quickly and safely. Once
the battery is fully charged a somewhat lower voltage is applied to maintain the battery in a fully charged
state without excessive water loss. The three stage charge process charges the battery as quickly as
possible while minimizing battery water loss and maintenance.
4.2.2.1 Bulk Stage
When charge starts the TrakMax attempts to apply the bulk charge voltage to the battery. The system will
switch to Bulk charge if the battery is sufficiently discharged and/or insufficient charge current is available to
drive the battery up to the bulk voltage set point.
During this stage, the batteries are charged at the bulk voltage setting. And the unit delivers as much charge
current as possible to rapidly recharge the batteries. When the battery voltage reaches the bulk voltage
setting, the charge controller activates the next stage (absorption). TrakMax will again switch to Bulk charge
if battery voltage drops below the present charge voltage set point.
4.2.2.2 Absorption Stage
During this stage, the unit changes to a constant voltage mode where the absorption voltage is applied to the
battery. When charge current decreases to the float transition current setting, the battery is fully charged and
the unit switches to the float stage.
4.2.2.3 Float Stage
During this stage, the float voltage is applied to the battery to maintain it in a fully charged state. When
battery voltage drops below the float setting for a cumulative period, a new bulk cycle will be triggered.
4.2.3 Equalization
Equalize charging is a special mode of battery charging. During use, the battery’s cells can become unequal
in the voltage and current they can deliver. This is due to a buildup of sulfate on the plates as well as
stratified electrolyte. Sulfate prevents the cells from receiving or delivering full power. If the sulfate is left on
the plates, it will harden, and permanently reduce the battery’s capacity. Stratification separates the heavier
acid from the water, and the concentrated acid remains at the lower portion of the plates, eventually
corroding them. Equalizing the batteries every month or two (depending on usage) prolongs the life of the
batteries and provides better battery performance.
To set the Equalize Charge:
1) Remove all DC loads connected to the batteries.
2) Remove all battery vent caps.
3) Check the battery water level; it should be just over the top of the plates (do not over fill). Use only
distilled water for filling batteries.
4) Set the BATTERY TYPE SELECTOR switch to position “0” or “1”.
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5) Reset the BATTERY TYPE SELECTOR potentiometer to the appropriate setting for the system
batteries when the Equalize charge has completed
4.3 DC LOAD CONTROL
The TrakMax can operate as a PV charge controller and can regulate up to 40 Amps of continuous
photovoltaic (PV) array current at 12 / 24-volts DC for charging batteries. At the same time the TrakMax can
provide a maximum of 15 Amps of current to a DC load, but the 40 Amp current rating is shared between the
battery and the DC load.
The TrakMax uses voltage set points to determine when to disconnect or reconnect loads depending on
battery voltage. TrakMax prevents damage to the battery from over-discharge during periods of poor weather
or excessive loads and can charge the batteries in this function.
4.3.1 Auto Night Disconnect
When using PV Charge Control mode, the PV array is automatically disconnected from the battery at night to
prevent reverse leakage of power and to protect the PV array.
4.3.2 Low Voltage Disconnect
When configured as a load controller, the TrakMax will disconnect the load from the batteries when it
reaches the low voltage disconnect (LVD) s ett ing . Ther e will be a 1-minute delay after the voltage drops
below the LVD setting before the controller actually disconnects the load.
4.3.3 Low Voltage Reconnect
The TrakMax will also provide automatic reconnection of the loads at the low voltage reconnect (LVR)
setting. Reconnection of the load is allowed once the battery voltage has exceeded the low voltage
reconnect (LVR) setting. Loads are automatically reconnected when battery voltage exceeds the low voltage
reconnect (LVR) setting for 1 minute.
Important: When using the TrakMax in load control do not install the BTS Battery Temperature Sensor
4.4 BATTERY SELECTION
It is important to select the battery type that matches the system battery to ensure proper charging and long
battery life. The battery type selector (Figure 4.4) is a 10 position rotary switch used to set the TrakMax for
the proper float and bulk voltage levels. These levels are selected depending on the type of batteries used.
Refer to the table below for the charge voltages in the various switch positions. Refer to the specifications
provided by the battery manufacturer and choose a setting that best fits the recommended charging profile.
4.4.1 Battery Type Selector Switch Settings
• Battery Type: The common battery type associated with the specified charging settings.
• Float Stage: When the battery is fully charged, the charging voltage will be reduced to the Float
voltage setting.
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Figure 4.4: Battery Type Selector
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Position
Battery Type
12 Volt
24 Volt
Charge Function
Float
(Volts)
Bulk
(Volts)
Float
(Volts)
Bulk
(Volts)
Equalize charge rate Time
Battery Capacity
Equalize Rate: Battery Capacity (A/hrs) / 40.
Battery Charger Rate
Charger Rate: Set by Battery Rate control.
Additional setting of Bulk and Float voltages.
Refer to battery manufacturer for settings.
Recommended for gel cell batteries that
Refer to battery manufacturer for settings.
Calcium
batteries.
Deep Cycle
Lead Acid 1
Factory Default Setting.
Typical deep cycle lead acid batteries.
batteries.
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• Equalize: During an equalization cycle, the charging voltage will be held constant at the specified
voltage setting.
Switch
Stage
Equalize
Stage
Equalize
0 Equalize 1 13.2 *15 26.4 *30
1 Equalize 2 13.2 *15.5 26.4 *31
Deep Cell
2
Lead Acid 2
13.3 15 26.6 30
6 hrs. (Min) / 12 hrs. (Max).
6 hrs. (Min) / 12 hrs. (Max).
Additional Float and Bulk settings for deep
cycle, lead acid batteries.
Refer to battery manufacturer for settings.
3 Not Specified 13.6 14.3 27.2 28.6
4 Gel Cell 2 13.7 14.4 27.4 28.8
specify high float voltages.
5 Gel Cell 1 13.5 14.1 27 28.2 Typical gel cell battery setting.
6
7
Default
PcCa Lead
13.2 14.3 26.4 28.6
13.4 14.6 26.8 29.2
Recommended for use with sealed type car
8 NiCad 1 14 16 28 32 Use for NiCad battery systems.
9 NiCad 2 14.5 16 29 32
Recommended for use with nickel iron
Important:
1) Switch positions “0” and “1” are for monthly battery maintenance only. Return the switch to the
appropriate position for the system’s batteries when Equalize charging has completed. NEVER
EQUALIZE GEL BATTERIES!
2) Equalize voltages are displayed in the table with an asterisk (*) – Switch positions “0” and “1” only.
3) Switch position “7” represents the default values as shipped from the factory.
4) Always refer to the battery manufacturer’s specifications for equalization.
5 LED INDICATORS
The TrakMax has one multicolor LED and one green LED to indicate the operating status of the controller.
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Battery Capacity:
<LVD
<LVR, >LVD
>LVR
LED Indication:
Single Color LED
Multi-Color LED
Description
Mode
State
On
Off
State
On
Off
∞
∞
∞ ∞
∞ ∞
∞ ∞
∞ ∞
7
Off
∞ ∞
Blink Orange
1s
6s
BAT under voltage
8
Blink Green
3s
6s
Off
∞
∞
Over Current
9
Blink Green
2s
6s
Off
∞
∞
Over Temperature
∞
∞
∞
∞
Upon start-up wait 3s.
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A solid green LED indicates the charging source is functioning properly. A flashing green LED indicates an
error condition exists. The multi-color LED indicates the particular operating mode and the batt ery capacity
level.
5.1 C
HARGE CONTROL
Red Orange Green
Figure 5.1: Battery Capacity LED indicators
5.2 LED MODES
If the single color LED or multi-color LED flashes, it indicates an error condition such as over temperature,
over current, low voltage disconnect, reverse connection for solar modules, and over voltage of load. The
green LED’s flash time depends on the condition or function they are displaying; See table 5.2.
Operation
1 Solid Green
2 Solid Green ∞ ∞ Solid Orange ∞ ∞ Charge ON (PV>BV), LVD<B AT<LVR
3 Solid Green ∞ ∞ Solid Green
4 Solid Green ∞ ∞ Blink Red 1s 1s Charge ON (PV>BV) , B AT<LVD
5 Solid Green
6 Solid Green
Solid Red
Blink Orange 1s 1s Charge ON (PV>BV) , LV D<BAT<LVR
Blink Green 1s 1s Charge ON (PV>BV) , B AT>LVR
Charge ON (PV>BV) , B AT<LVD
Charge ON (PV>BV), BAT>L VR
NORMAL
DERATED
10 Blink Green 1s 6s Off
11 Blink Green 1s 1s Blink Red 1s 1s PV over voltage
12 Blink Green 1s 1s Blink Orange 1s 1s PV under voltage
13 Blink Green 1s 6s Blink Red
14 Blink Green
NOTE: When the controller is charging, the green LED will be solid green.
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∞ ∞
Blink Red
Table 5.2: Error Mode Indications
Over Voltage of Load
BAT over voltage
∞ ∞
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Problem
Possible Remedies
No LED indications, controller
• Check the voltage at the battery terminals on the TrakMax. Battery voltage
36 VDC and no LEDs are lit, contact your dealer for service.
Charge status LED on, but no
• Is the battery voltage greater than the charge voltage set point? This is
• Battery voltage must be at least 9VDC for the unit to operate.
Unit is on, but charge status
• Check PV connections for reverse polarity.
and current measurement system. Battery voltage is determined
Revision 1.0
5.2.1 Low Voltage Disconnect (LVD)
When a DC load is connected, if voltage remains below the Low Voltage Disconnect setting, the controller
will disconnect after a 6-minute delay period. The controller will wait until the voltage rises above the Low
Voltage Reconnect setting.
5.2.2 Over Voltage of Load
If the controller detects an over voltage of load, it will disconnect the load
5.2.3 Over Temperature
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 mode, the controller will decrease the charge current to reduce the transistor temperature and the
green led will be solid green. If the TrakMax is connected with a DC load, the load is disconnected before the
transistors reach an excessive tem per atur e and the green LED flashes. Once the temperature has dropped,
the loads are reconnected.
5.2.4 Over Current of Load
If the controller detects an overload or short circuit on the load, it will automatically reset the over current
protection system every 6 minutes. If the default is still present, the controller will shut off and wait another 6
minutes. This will occur continuously until the problem is corrected.
6 TROUBLESHOOTING AND SUPPORT
The TrakMax is ruggedly constructed and requires minimal care. It is recommended to inspect all the
controller connections two times per year for insulation damage or corrosion and to ensure all connections
are tight and secure.
CAUTION: Shock Hazard
Disconnect all power sources to the controller before removing the wiring box cover. Never remove the cover
when voltage exists on the power connections.
6.1 CARE
Clean the heat sink and area around the controller of any dirt or debris with a moistened cloth.
Inspect the battery bank for cracked or bulging cases and corroded terminals.
For wet cell flooded batteries, make sure the water level is maintained according to the manufacturer’s
recommendations.
6.2 TROUBLESHOOTING
does not appear to be powered
output charge current
must be a constant 12 VDC or greater. If no voltage is measured, check
wiring connections, fuses, and breakers.
• If the voltage on the battery terminals of the controller is between 12 and
normal operation. Output is off due to high battery voltage which may be
caused by other charging systems.
LED is off
• PV must supply at least 0.25Amp at 3V more than battery voltage to begin
charge.
• PV- & BAT- must be separate for proper operation. PV- must receive earth
ground via shunts inside the TrakMax which inter n al l y connect PV- to
BAT-. External connection prevents proper operation of internal shunts
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automatically when the unit first receives power. PV open circuit voltage
24VDC battery charging.
Charge current or PV current is
• Check battery voltage, current is reduced if battery voltage is at set points.
battery charging if PV voltage ever goes above 30VDC.
Charge OFF at high temperature
The system temporarily shuts down due to high heat sink temperatures.
Improve ventilation or reduce PV power to prevent over temp shut down.
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must be 12-30VDC for 12VDC battery charging, and 30-55VDC for
lower than expected
• Check atmospheric haze, dirty PV’s, or sun low on horizon, etc.
• Check PV voltage; if system has been changed from 24VDC to 12VDC (or
vice versa), battery and PV power must be momentarily disconnected
from the TrakMax to reboot the unit and load initial 12 or 24VDC control
values. TrakMax considers the PV array to be configured for 24VDC
6.3 SUPPORT
If you are experiencing technical problems, and cannot find a solution in this manual, you can contact Windy
Nation Inc. for further assistance.
• Call: (805) 323-6445
• Email: info@windynation.com
• Write: 1082 Front Street, Unit B, Ventura, CA 93001
For challenging issues or to just ask a question, consider using our FREE Community Forums! Consult our
community of DIY'ers for fast answers to all your questions.
Post on our Forums: http://www.windynation.com/community/
7 BATTERIES
Batteries come in different sizes, types, amp-hour capacity, voltages and chemistries. Here are a few
guidelines that will help in battery selection, and ensure that the batteries are properly maintained. The best
source of the most appropriate settings for the TrakMax will be from the manufacturer or supplier of the
batteries.
7.1 BATTERY TYPES
7.1.1 Automotive Batteries
Automotive and truck batteries are designed for high cranking power – not deep-cycling. Do not use them
unless no other battery type is available. They simply will not last long in a cycling application.
7.1.2 Maintenance-Free Batteries
This type of battery is often sold as a RV or marine battery, but is rarely appropriate for use with a PV
system. They typically have an additional reserve of electrolyte, but are vented. This is not the same as a
sealed battery.
7.1.3 Deep-Cycle Batteries
Best suited for use with PV systems, this type of battery is designed to be more deeply discharged before
being recharged. Deep-cycle batteries are available in many sizes and types. The most common is the
vented liquid electrolyte battery. Vented batteries usually have battery caps. The caps may appear to be
sealed, but are not. The caps should be removed periodically to check the level of electrolyte. When a cell is
low, distilled water should be added after the battery is fully charged. If the level is extremely low, add only
enough distilled water to cover the plates before recharging. The electrolyte volume increases during the
charging process and the battery will overflow if it is filled all of the way up before recharging. Use only
distilled water because im puriti es will reduce battery performance. A popular and inex p ens ive dee p-cycle
battery is the “golf cart” battery. It is a 6-volt design, typically rated at 220amp-hours. RV and marine deepcycle batteries are also popular for small systems. They are usually referred to as Group 24 or Group 27
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Battery Type
Bulk Volts
Float Volts
Equalizing Charge
Default Settings
14.0 VDC
13.5 VDC
Disabled
Sealed Gel Lead Acid
14.1 VDC
13.6 VDC
Not recommended; Consult battery manufacturer
AGM Lead Acid
14.4 VDC
13.4 VDC
Charge to 15.5 VDC or per manufacturer.
Maintenance-Free
RV/Marine
Deep-Cycle, Liquid
Electrolyte Lead Antimony
NiCad or NiFe Alkaline
16.0 VDC
14.5 VDC
Not recommended; Consult battery manufacturer
Revision 1.0
batteries and are rated at 80 to 100 amp-hours at 12volts. Many larger systems use L16 batteries, which are
usually rated at 350amp-hours at 6-volts each. They are 17 inches high and weigh about 130pounds. 8D
batteries are available with either cranking or deep-cycle construction. Purchase only the deep-cycle version.
The 8D is typically rated at 220 amp hours at 12 volts.
7.1.4 Sealed Batteries
Another type of battery construction is the sealed gel cell. They do not use battery caps. The electrolyte is in
the form of a gel rather than a liquid, which allows the batteries to be mounted in any position. The
advantages are no maintenance, long life (800 cycles claimed) and low self-discharge. Absorbed glass mat
(AGM) electrolyte batteries are also acceptable. Their electrolyte is contained in mats between the battery
plates. Sealed batteries reduce the maintenance requirements for the system and are good for remote
applications. They are much more sensitive to the charging process and can be ruined in as little as a day of
overcharging.
7.2 BATTERY SIZING
Batteries are the fuel tank of the system. The larger the batteries, the longer the system can operate before
recharging is necessary. An undersized battery bank results in short battery life and disappointing system
performance. To determine the proper battery bank size, compute the number of amp-hours that will be used
between charging cycles. Once the required amp-hours are known, size the batteries at approximately twice
this amount. Doubling the expected amp-hour usage ensures that the batteries will not be overly discharged
and will extend battery life.
7.3 EQUALIZATION CHARGING
Approximately ever y month, some batteries may need to be “equalized.” Since the individual cells of the
battery are not identical, some cells may not be fully charged when the charging process is completed. If the
batteries have been left in a discharged condition for long periods of time, the plates will have sulfates on
them from the electrolyte. If the sulfate remains on the plates for an extended period of time, it will harden
and seal off a percentage of the plate area, reducing the capacity of the battery. By equalizing the batteries
before the sulfate hardens, the sulfate is removed from the plates. Batteries with liquid electrolyte may
become stratified. Stratification concentrates the sulfuric acid into the bottom of the cell while the top
becomes diluted. This corrodes the lower portion of the plates, reducing battery life. Mixing of the electrolyte
by the formation of gas bubbles during the equalization process reduces stratification. Two methods can be
used to determine if a battery needs to be equalized. If possible, measure the voltage of each individual cell
while the battery is at rest (not being charged or discharged). A variation of 0.05 volts between cells indicates
an imbalance exists. If the battery construction prevents measurement of the individual cell voltages, use a
hydrometer. A variation of 0.020 in the specific gravity between cells is considered significant. Both
conditions can be corrected by an equalization charge. A proper equalization charge will not damage a
vented, liquid electrolyte type battery. It may, however, cause significant electrolyte usage and require that
the battery be refilled with distilled water to the correct level. This may be a problem with unattended systems
in remote areas which do not receive regular maintenance. Consult the battery manufacturer for their
recommendations.
7.3.1 Equalization Set Points (Non-Sealed Batteries Only)
14.4 VDC 13.4 VDC Limited Only if water level can be checked.
14.6 VDC 13.4 VDC Charge to 15.5 VDC or per manufacturer.
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