Xantrex C35, C40, C60 Owner's Manual

Smart choice for power

e

C-Series
Multifunction
DC Controller

C35
C40
C60

Owner’s Manual

Manual Typ

www.xantrex.com

C-Series Multifunction
DC Controller

Owner’s Guide

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power
electronics and controls with products from 50 watt mobile units to one MW
utility-scale systems for wind, solar, batteries, fue l cells, microturbines, and
backup power applications in both grid-c onnected and stand-alone s ys tems.
Xantrex products include inverters , battery chargers, programmable power
supplies, and variable speed drive s that convert, supply, control, clean, and
distr ib u t e el ec tr i cal powe r.

Trademarks

C-Series Multifunction DC Controller is a trademark of Xantrex International.

Xantrex is a regis tered trademark of Xantrex Intern ational.
Other trademarks , registered trademark s, and product names are the property of

their respe ctive owners and are used herein for ide ntification purposes only.

Notice of Copyright

C-Series Multif unct io n DC Contr oll er Owner’ s Gui de © November 200 3 Xantrex

Internationa l. All rights reserved.

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC.
(“XANTREX”)

(a) MAKES NO WARRANTY AS TO THE ACCURACY , SUFFICIENCY OR SUITABILITY OF
ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER
DOCUMENTATION.

(b) AS SUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER
DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF
THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE
ENTIRELY AT THE USER’S RISK.

Date and Revision

November 2003 Revision D

Part Number

975-0004-01-02 Rev D

Contact Information

Telephone: [phone] (toll free North Ame rica)

1 360 925 5097 (direct )

Fax: [phone] (toll free North Amer ica)

1 360 925 5143 (direct )
Email: [e-mail]
Web: www.xantrex.com

About This Guide

Purpose

The purpose of this Guide is to provide explanations and
procedures for installing, operating, maint aining, and
troubleshooting the C-Series Multifunction DC Controller.

Scope

This Guide provides safety guidelines, detailed planning and
setup information, procedures for installing the inverter, as
well as information ab out operating and troubleshooting the
unit. It does not provide details about particular brands of
batteries. You need to consult individua l battery
manufacturers for this information.

Audience

This Guide is intended for anyone who needs to install and
operate the C-Series Multifunction DC Controller. Installers
should be certifi ed technicians or electrici ans.

Organization

This Guide is orga nized into four chapters and three
appendices.

Chapter 1 describes fea tures and functions of the C-Series
Multifunction DC Controller.

iii

About This Guide

Chapter 2 contains inf ormation and procedures to install
C-Series Multifunction DC Controller.

Chapter 3 contains inf ormation about the operation of a
C-Series Multifunction DC Controller.

Chapter 4, “T r oubleshooting” contains information about
identifying and resolving possible problems with systems
using a C-Series Multif unction DC Controller.

Appendix A, “Specifications” provide the specifications for
the C-Series Multif unction DC Controller.

Appendix B, “Batteries” describes types of batteries.
Appendix C, “Diversi on Loads” provides additional

information about Diversion Loads.

Conventions Used

The following conventions are used in this guide.

WARNING

Warnings identify conditions that could result in personal injury or
loss of life.

CAUTION

Cautions identify condit ions or practices that could result in
damage to the unit or to other equipment.

Important:

an item that you must pay attention to.

These notes desc ribe an important action item or

iv 975-0004-01-02 Rev D

Abbreviations and Acronyms

ASC Authorized Service Center
BTS Battery Temperat ure Sensor
CM C-Seri es Meter
CM/R C-Series Meter - Remote
DC Direct Current
LCD Liquid Crystal Display
LED Light Emitting Diode
LVD Low Voltage Disconnect
LVR Low Voltage Reconn ect
RE Renewable Energy

About This Guide

Related Information

You can find more information about Xantrex Technology
Inc. as well as its products and services at

www.xantrex.com.

975-0004-01-02 Rev D v

vi

Important Safety Instructions

WARNING

This manual contains important safety instructions that should be
followed duri ng the installa tion and maint enance of this produ ct. Be

sure to read, understand, and sav e the se safety instructions.

General Safety Instructions

• All electrica l wo rk mus t be done in accordanc e wit h
local, nati ona l, a nd/or international electr ical codes.

• Before insta lling or using t his device, read a ll instruct ions
and cautionar y markings locat ed in (or on) this guide, the
controller, the batteries, PV array, and any other
equipment used.

• This product is designed for indoor mounting only. Do
not expose this unit to rain, snow or liquids of any type.
In outdoor installations, the C-Series controller must be
installed i n a rainpr oof enc losu re to e limina te exposu re t o
rain or water-spray.

• To reduce t he chance of shor t-cir cuits, use insul ated t ools
when installing or working with the inverter , the
controller, the batteries, or any DC source (e.g., PV,
hydro, or wind).

• Remove all jewelr y. This will greatly reduce the chance
of accidental exp osure to live circuits.

• The controlle r contains more than one live circuit
(batteries and PV array , wind, or hydro). 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.

975-0004-01-02 Rev D vii

Safety

Battery Safety Information

• Always wear eye protection, such as safety glasses, when
working with batteries.

• Remove all jewelr y 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 lif ting techniques when handling
batteries.

• Always use ident i cal typ es o f ba tter ie s.

• Never instal l old or untested batteries. Check each
battery’s date code or label to ensure age and type.

• Batteries should be installed in a well-vented area to
prevent the possible buildup of explosive gasses. If the
batteries a re insta lled ins ide an enc losu re, vent its h ighe st
point to the outdoors.

• When installing batteries, allow at least 1 inch of air
space between batter ies 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-cir cuit 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 at tention.

• Always recycle old batteries. Contact your local
recycling cen ter fo r pro p er disp o sal information.

viii 975-0004-01-02 Rev D

Battery Safety Information

CAUTION:

A battery can produce the following hazards to personal safety:

• electrical shock,

• burn from high-short -circuit current, and/o r

• fire or explosion from vented gasses.

Observe proper precautions when working with or aroun d batteries.

975-0004-01-02 Rev D ix

x

Contents

Important Safety Instructions

1

Introduction

Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Operating Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

Charge Control Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Three-Stage Batt ery Ch ar g ing- - - - - - - - - - - - - - - - - - - 4
Battery Temperature Compensation - - - - - - - - - - - - - - - 6
Manual or Auto Equalization Charge - - - - - - - - - - - - - - 6

Load Control Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

Controller Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

Photovoltaic Charge Controller - - - - - - - - - - - - - - - - - - - - - 7

Automatic PV Array Night Disconnect- - - - - - - - - - - - - 8

Diversion Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

Diversion Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Load Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

- - - - - - - - - - - - - - - - - -vii

Low Voltage Disconnect - - - - - - - - - - - - - - - - - - - - - 11
Low Voltage Reconnect- - - - - - - - - - - - - - - - - - - - - - 11

Optional Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

2

Installation

Pre-Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14

Removing the Top Cover- - - - - - - - - - - - - - - - - - - - - - - - 14
Removing Knockouts - - - - - - - - - - - - - - - - - - - - - - - - - - 14
Mounting the Controller - - - - - - - - - - - - - - - - - - - - - - - - 16

Configuring the C-Series Controller - - - - - - - - - - - - - - - - - - - 18

Jumper Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Operating Mode Jumper- - - - - - - - - - - - - - - - - - - - - - 20
Voltage Jumper- - - - - - - - - - - - - - - - - - - - - - - - - - - - 20

xi

Contents

Automatic/Manual Battery Equalization (EQ) and Low

Voltage Reconnect (LVR) Jumper- - - - - - - - - - - - - - 21

Adjusting the C-Serie s Voltage Settings- - - - - - - - - - - - - - - - - 22

Setting Voltage Parameters for Charge Control Mode- - - - - 22
Setting Voltage Parameters for Load Control Mode - - - - - - 24
Setting Voltage Parameters Diversion Control Mode - - - - - 26
Setting Voltage Parameters for Alkaline Batteries - - - - - - - 26
Using a Digital Voltmeter to Adjust Voltage Settings- - - - - 28

Equalization Charging- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30

Manual Equalization - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
Automatic Equalization - - - - - - - - - - - - - - - - - - - - - - - - - 32
Termin at ing the E qu al izat i on Process - - - - - - - - - - - - - - - 3 3

Temperature Compensation - - - - - - - - - - - - - - - - - - - - - - - - - 33

Temperature Compensa tion Based on Battery Type - - - - - - 34
Automatic Battery Temperature Compensation - - - - - - - - - 34

Manual Battery Temperature Compensation - - - - - - - - - - - 36
Grounding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38

DC Terminal Connector Locations - - - - - - - - - - - - - - - - - 38

Terminal Torque Requirements- - - - - - - - - - - - - - - - - 39

Wire Size and Over-curre nt Protection Requirements- - - - - 39

Current Rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39
Minimum Recommended Wire Gauge - - - - - - - - - - - - 40
Surge Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
Over-current Protection - - - - - - - - - - - - - - - - - - - - - - 41
Long-distance wire runs- - - - - - - - - - - - - - - - - - - - - - 42

Maximum One-w ay D i stance and Wire Size - - - - - - - - 42
PV Charge Control Mode Wiring - - - - - - - - - - - - - - - - - - 44
Diversion Control Mode Wiring - - - - - - - - - - - - - - - - - - - 46
DC Load Co ntr ol Mo de W i rin g- - - - - - - - - - - - - - - - - - - - 48

Installing Optional Accessories- - - - - - - - - - - - - - - - - - - - - - - 50

Installing a Digital Display- - - - - - - - - - - - - - - - - - - - - - - 50
Installing the Battery Temperature Sensor - - - - - - - - - - - - 51

Reinstalling the Faceplate - - - - - - - - - - - - - - - - - - - - - - - - - - 52

xii 975-0004-01-02 Rev D

3

Operation

Basic Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
LED Status Indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

Charge Control or Diversion Control Indications (Green) - - 56

Blinking Green- - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

Solid Green - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

Equalization Mode Indication (Red/green) - - - - - - - - - 58
Load Control Indications (Red)- - - - - - - - - - - - - - - - - - - - 58

Blinking Red - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

Solid Red- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
Error Mode Indication (Orange) - - - - - - - - - - - - - - - - - - - 59

Over-temperatur e Condition - - - - - - - - - - - - - - - - - - - 59

Over-Current Condition- - - - - - - - - - - - - - - - - - - - - - 59

Low-voltage Disconnect Con dition - - - - - - - - - - - - - - 60

Reconnecting to Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60

Contents

Reset Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

4

Troubleshooting

PV Charge Control Troubleshooting - - - - - - - - - - - - - - - - - - - 64
Diversion Control Troubleshooting - - - - - - - - - - - - - - - - - - - - 66
Load Control Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - 68

A

Specifications

Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - 70
Features and Options Specifications - - - - - - - - - - - - - - - - - - - 71
Environmental Specifications- - - - - - - - - - - - - - - - - - - - - - - - 72

B

Batteries

Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 74

Automotive Batteries- - - - - - - - - - - - - - - - - - - - - - - - - - - 74
Maintenance-Free Batteries - - - - - - - - - - - - - - - - - - - - - - 74
Deep-Cycle Batteries- - - - - - - - - - - - - - - - - - - - - - - - - - - 74
Sealed Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75
NiCad and NiFe Batteries - - - - - - - - - - - - - - - - - - - - - - - 76

975-0004-01-02 Rev D xiii

Contents

Battery Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76
Equalization Charging- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77

Equalization Setpoints (Non-Sealed Batteries Only)- - - - - - 79

C

Diversion Loads

Diversion Load Types- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82

Warranty and Product Information

Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
Disclaimer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86
Return Material Authorization Policy - - - - - - - - - - - - - - - - - - 87
Return Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88
Out of Warranty Service - - - - - - - - - - - - - - - - - - - - - - - - - - - 88
Information About Your System - - - - - - - - - - - - - - - - - - - - - 89

Index

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91

xiv 975-0004-01-02 Rev D

Figures

Figure 1-1 C-Series Multifunction DC Charge Controllers - - - - - - 2
Figure 1-2 3-stage Battery Charging Process - - - - - - - - - - - - - - - 5
Figure 1-3 PV Charge Controller - - - - - - - - - - - - - - - - - - - - - - - 7
Figure 1-4 Diversion Controller - - - - - - - - - - - - - - - - - - - - - - - - 9
Figure 1-5 Load Controller - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Figure 1-6 Decal Displaying Load Control Voltage Settings - - - - 12
Figure 1-7 Optional Accessories - CM/R, CM, and BTS- - - - - - - 12
Figure 2-1 Removing the Front Cover - - - - - - - - - - - - - - - - - - - 14
Figure 2-2 C-Series Dimensions and Knockout Locations

(Not to Scale)- - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
Figure 2-3 Mounting the C-Series Multifunction DC Controller - 17
Figure 2-4 Jumper Positions- - - - - - - - - - - - - - - - - - - - - - - - - - 18
Figure 2-5 Circuit Board Co m p one n ts - - - - - - - - - - - - - - - - - - - 1 9
Figure 2-6 Mode of Operation Jumper- - - - - - - - - - - - - - - - - - - 20
Figure 2-7 Voltage Selection Jumper- - - - - - - - - - - - - - - - - - - - 20
Figure 2-8 EQ/LVR Jumper and Reset Switch - - - - - - - - - - - - - 21
Figure 2-9 B ulk and Float Charge Potentiometers (pots)- - - - - - - 22
Figure 2-10 Bulk and Float Charge Settings for Charge/Diversion

Control Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
Figure 2-11 Potentiometers with Decal for LVR and LVD Settings 24
Figure 2-12 LVR and LVD Settings for Load Control Mode- - - - - 25
Figure 2-13 R46 Resistor Location - - - - - - - - - - - - - - - - - - - - - - 26
Figure 2-14 Voltage Settings with R46 Resistor Clipped - - - - - - - 27
Figure 2-15 Test Points for Adjusting Voltage Using a DVM - - - - 29
Figure 2-16 Manual Equalization Settings - - - - - - - - - - - - - - - - - 30
Figure 2-17 Front Panel LED and Reset Switch Location- - - - - - - 31
Figure 2-18 Auto Equalization Settings - - - - - - - - - - - - - - - - - - - 32
Figure 2-1 9 Terminating the Eq u aliz at ion Ch a rg e - - - - - - - - - - - - 33
Figure 2-20 Grounding the C-Series Chassis - - - - - - - - - - - - - - - 37
Figure 2-21 DC Connection Terminals - - - - - - - - - - - - - - - - - - - 39

xv

Figures

Figure 2-22 AWG Wire Gauge Reference Chart - - - - - - - - - - - - - 40
Figure 2-23 PV Charge Control Mode Wiring - - - - - - - - - - - - - - 45
Figure 2-24 Diversion Control Mode Wiring - - - - - - - - - - - - - - - 47
Figure 2-2 5 Load Control Mo de W i rin g - - - - - - - - - - - - - - - - - - 49
Figure 2-2 6 Installing a Dig ital D isp lay- - - - - - - - - - - - - - - - - - - 50
Figure 2-27 Installing the BTS- - - - - - - - - - - - - - - - - - - - - - - - - 51
Figure 2-28 Re-installing the CM Faceplate - - - - - - - - - - - - - - - - 52
Figure 3-1 C -Series Status LED and Reset Button Location - - - - 54
Figure 3-2 C- Ser ie s Fr ont Pan e l Lab el- - - - - - - - - - - - - - - - - - - 55
Figure 3-3 Reset Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

xvi 975-0004-01-02 Rev D

Tables

Table 2-1 Factory Def aul t Se ttin gs for C-Series Con tro l lers- - - - 19
Table 2-2 Variances in Charging Volta ge based on

Battery Temperature - - - - - - - - - - - - - - - - - - - - - - - 35
Table 2-3 Minimum Wire Size - - - - - - - - - - - - - - - - - - - - - - - 41
Table 2-4 One-Way Wire Distance and Wire Size - - - - - - - - - - 43
Table 3-1 Battery Voltage LED Indicators - - - - - - - - - - - - - - - 56
Table 4-1 PV Charge Control Problems - - - - - - - - - - - - - - - - - 64
Table 4-2 Diversion Control Problems - - - - - - - - - - - - - - - - - - 66
Table 4-3 Load Control Problems - - - - - - - - - - - - - - - - - - - - - 68
Table A-1 Electrical Specifications- - - - - - - - - - - - - - - - - - - - - 70
Table A-2 Features and Options Specifications- - - - - - - - - - - - - 71
Table A-3 Environmental Specifications - - - - - - - - - - - - - - - - - 72
Table B-1 Typical Bulk and Float Setpoints for Batteries- - - - - - 79
Table C-1 Power Dissipation- - - - - - - - - - - - - - - - - - - - - - - - - 82

xvii

xviii

1

Chapter 1 describes features and functions of the

C-Series Multifunction DC Controller.

For information on: See:

“Features” page 2
“Operating Modes” page 3
“Controller Functions” page 7
“Optional Accessories” page 12

Introduction

Introduction

Features

The C35/C40/C60 (C-Series) controllers can be used with
12-volt, 24-volt, or 48-volt DC systems (depending upon
model) as Charge Controller or a Load Controller.

C35

Figure 1-1

C40

C-Series Multifunction DC Charge Controllers

C60

Numerous features are provided standard to maximize the
performance of t he system:

• Solid-state Pulse Width Modulated (PWM) charging
process w ith three-stage co ntr o l, temp era ture
compensation, and manual or automatic equalization to
maximize system performance and increase battery life.

• Multi color LED with easy to read mode/status label.

• Electronic overload and short-circuit protection with
automatic and manual rese t capability increases the
reliability of unattended systems by eliminating blown
fuses and tripped cir cuit breakers.

• Adjustment of charge setpoints is provided by rotary
controls (potentiometers) with removable knobs.
Calibrated scales and test points allow precise
adjustments of settings.

• Over-temperature protection for the electronic circuitry
when used in hot environments (over 113 °F/45 °C).

2 975-0004-01-02 Rev D

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

• Conformal-coated circuit boards, plated terminals,
powder-coated metal components, and stainl ess steel
fasteners improves tolerance to hostile environments.

• Meets National Ele ctrical Code (NEC) and other
internat ional co ntr o ller specifi ca tio n s.

• The C35, C40 and C60 models are UL listed to the
U.S. UL Standard 1741 (1st edition), and Canada
(CSA-C22.2 No. 107.1- 95).

• 2-year limite d warranty.

Operating Modes

The DC controller is a criti cal component in any solar, wind

Operating Modes

or hydro power generation system and protects the batteries
from over-discharge and over -charge conditions. The

C-Series has two operating modes (Char ge Contr ol mode and

Load Control mode determined by the Operating mode
jumper (See Figure 2-5). These two different operating
modes allow t he C-Serie s to be inst alled and funct ion as three
different DC controllers.

• Charge Co ntro l Mode

• PV Charge Contro ller - controls charging in PV

installations.

• Diversion Controller – used in PV, wind, or hydro

installations to divert any excess energy to a diversion
load and in the case of a wind or hydro generator, helps
to prevent over-spin damage.

• Load Control Mode

• Load Controller - prevents damage to the battery from

over-discharge during periods of poor charging or
excessiv e loa ds.

975-0004-01-02 Rev D 3

Introduction

Important:

than one func tion at the same time. If several functions are
r equir e d in a sys tem, a dedicat ed controller must be used for each
function.

The C-Series controller cannot ope rate in more

Charge Control Mode

In the Charge Control mode, the C-Series controls how the
batteries are charged by the DC source (solar, wind, or
hydro). I t uses a 3-sta ge ch arging pr otocol t o maint ain batte ry
voltage at bulk and/or float levels.

When charging, the C-Series controller monitors the batt eries
and depending on how it is wired will r egulate t he PV current
(as a PV Charge Controller) or divert excess ener gy from PV,
hydro, or wind to a DC load (as a Diversion Controller) and
allows the battery to charge according to user-defined
settings based on the amount of DC power available .

When the C-Series operates in the Charge Control mode, it
provides:

• three-stage charging of batte ry vol tage,

• automatic temperature compensation (if the BTS is used),
and

• automatic or manual equalization charging.

Three-Stage Battery Charging

The three-stage charging process results in faster charging
compared to on-off relay type or constant voltage solid-state
regulators. Faster recharging increases the performance of the
system by storing more of the PV array’s limited output. The
final float volta ge setting reduces battery gassing, minimizes
watering requirements and ensures complete battery
recharging. The C-Series will use this protocol in either PV
Charge Control mode or in Diversion Control mode. It does
not charge the batteries when in Load Control mode. Battery
voltage and curren t vary during the three-stage char ging
process as follows.

4 975-0004-01-02 Rev D

Bulk Stage

During this stage, the batteries are charged at the bulk voltage
setting and maximum current output of the DC source. When
the battery voltage reaches the bulk voltage setting, the
controller activates the next stage (absorption).

Absorption Stage

During this st age, the vo ltage of the ba tter y is held at the bulk
voltage setting until an internal timer has accumulated one
hour. Current gradually declines as the battery capacity is
reached.

Float Stage

During this s tage, the vol tage of t he battery i s he ld at the f loat
voltage setting. Full current can be provided to the loads
connected to the battery during the float stage from the PV
array. When battery voltage drops below the float setting f or
a cumulative perio d of one hour, a new bulk cycle will be

Operating Modes

Charging

Started

DC Voltage

0 volts

DC Current

0 amps

Time

Figure 1-2

triggered.

Bulk Stage

Increasing V oltage Constant Voltage Reduced Voltage

Max Amps

Constant Current Reducing Current Reduced Current

Absorption Stage

Bulk Volts Setting

Absorption Time

3-stage Battery Charging Process

Float Stage

Float Volts Setting

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Introduction

Battery Temperature Compensation

The optional Battery Temperature Sensor (BTS)
automatically adjusts the charging process of the C-Series

controller. With t he BT S inst a l l e d , th e C-Series will increase

or decrease the batt ery charging voltage dependi ng on the
temperature of the battery to optimize the charge to the
battery and maintain optimal performance of the battery.

If not using the BTS, the voltage settings for charging will
need to be adjusted based on the tempera ture of the
environment around the batteries and on the type of batteries
being used.

See “Temperature Compensation” on pa ge 33 for information
on how to set the voltage.

Manual or Auto Equalization Charge

The C-Series controller can be used to manually or
automatically provide the battery bank with an equalize
charge. Factory default setting is for MANUAL Equal ization
charging. Be sure to be familiar with all the cautions and
warnings concerning equalization charging batteries or
damage to batteries can occur.

Load Control Mode

In the Load Control mode, the C-Series controls when to
remove a load or loads fro m the system when an
over-discharge or over-load situation occurs. The C-Series
controller uses the user-adjustable setpoints to determine
when to connect or reconnect loa ds depending on battery
voltage. A load controller prevents damage to the battery
from over-discharge during periods of poor weather or
excessiv e loa ds. The u nit doe s no t charg e the bat teri es whe n
in this function.

6 975-0004-01-02 Rev D

Controller Functions

The C-Series can be configured to function as three different
controllers:

• PV Charge Controller (Charge Control mode)

• Diversion Controller (Charge Control mode)

• Load Controller (Load Control mode)

Photovoltaic Charge Controller

The C-Series controller can operate as a Photovoltaic Charge
Controller, also called a “series re gulator”. 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 C35 m odels) , or 12-, 24- or 48-volts DC (C40 model)

Controller Functions

Figure 1-3

for charging batteries. This rating includes the NEC required
derating.

PV Charge Controller

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 te mperature. This will take several minutes to
occur, depending upon the ambient temperature involved.
When the heat si n k reach es the max imu m saf e temp era ture,
the controller will reduce the current, cooling the transistors
and the heatsink.

975-0004-01-02 Rev D 7

Introduction

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 m inutes (if overcurrent condition is no longer present).

See “Operati ng Mode Jumper ” on page 20 for information on
configuring this function.

Automatic PV Array 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 . This eliminates the need
for a blocking diode between the battery and the PV array. If
thin-film or amorph ous solar modules are being used, diodes
may still be required to prevent damage from partial shading
conditions.

Check the documentation pr ovided with the PV modules.

Diversion Controller

The C-Series controller can operat e as a Diversion Controll er,
also called a shunt reg ulator , to manage battery char ging from
alternative energy sources such as PV, wind or hydroelectric
generators. A diversion controller monitors battery voltage
and, when the voltage exceeds the settings for your charge
stage (whether bulk or float), the power is diverted from the
source (solar, wind, or hydro generator) to a “dump” load
which will dissipate the excess power into heat.

When used for this purpose, the C-Series controller varies an
amount of battery voltage to a “dump load” in order to
redirect the exce ss power generated from over-cha rging the
batteries. This allows the charging source to remain under
constant loa d to prev ent an over -speed c ondit ion which could
occur if the charging source is suddenly disconnected from
the battery–a s series regulators do.

Consult your dealer for recommendations on diversion load
type and regulator siz e.

8 975-0004-01-02 Rev D

Controller Functions

Figure 1-4

Diversion Controller

Diversion Loads

Diversion con trol requ ires a se parate “ dump” load t o regul ate
the battery. This load must be able to abso rb more po wer than
the charging source is able to produce at its peak output, or
the DC voltage will become unregula ted. The dump load
must be available for the diversion of power at all times.

Resistive-type heating elements are the best diversion loads.
Special direct-current w at er heat in g elem en t s are av ai lab le .
Light bulbs and motors are not rec ommended as diversion
loads because they are unreliable. A diversio n load that draws
about 25% more current than the char ging source’ s maximum
output capability is usually suitabl e for use with the C-Series

controller.

See Appendix C, “Diversion Loads” for additional
information on types of diversion loads.

See “Operating Mode Jumper” on page 20 for instructions on
enabling this mode.

975-0004-01-02 Rev D 9

Introduction

Important:

may be necessary to install diodes to prevent night-time
back-feed. If in doubt, contact or consult with your local
renewable energy expert.

Important:

to pre v en t back fe ed .

If PV arrays are used with diversion control, it

If using multiple RE sources, use diodes/isolatio n

CAUTION: Damage to Batteries

Current dra w of the di ver sion l oad is very import ant. Pr oble ms may
arise from operating with a load that is too s mall or too large. A
diversion load that is too sma ll will not be able to absorb all the
excess power fr o m the current source once the batteri es are full
allowing ba tteries to overcharge.

Diversion loads in excess of the controller ’s rating are capable of
absorbing more power than the C-Series control ler is designed to
handle, re sult ing in an ove r -curr ent shut down. Dur ing thi s ti me, the
unit will not regulate electrical flow in the system and battery
damage may result.

Load Controller

The C-Series controller can opera te as a Low Vol ta ge
Disconnect (LVD) for DC loads to prevent over-discharge to
batteries during periods of poor charging or exces sive loads.
The C-Series contro ller uses the user-adjusta ble setpoints to
determine when to discon nect or reconnect loads depending
on battery voltage .

When used as a DC load controller, the settings of the LVR
and LVD are controlled by two rotary potentiometers (also
called pots) on the circuit board.

The scale on the adjustment potentiometers differ from the
scale used for other fun ctions. A decal with the appropriate
adjustment scale is included with the C-Series. To apply the
decal, gently pull off the knobs of the potentiometers and
place this decal on the cir cuit board. After the decal is in
place, repl ace the knobs. The EQ jumper determines manual

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