Xantrex XW-MPPT-60-150 User Guide
SolarSurveyor_RevA.book Page i Friday, December 1, 2006 4:32 PM
Smart choice for power
Solar Charge
Controller
XW-MPPT-60-150
Owner’s Manual
T
F
A
DR
www.xantrex.com
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SolarSurveyor_RevA.book Page i Friday, December 1, 2006 4:32 PM
Solar Charge Controller
Owner’s Guide
SolarSurveyor_RevA.book Page ii Friday, December 1, 2006 4:32 PM
About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 1 MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.
Trademarks
Xantrex is a registered trademark of Xantrex International.
Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only.
Notice of Copyright
Solar Charge Controller Owner’s Manual © December 2006 Xantrex International. All rights reserved.
Exclusion for Documentation
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) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, 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; AND
(C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED
XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT www.xantrex.com.
Date and Revision
December 2006 Revision A
Part Number
975-0283-01-01 Rev A5 DRAFT
Product Number
865-1030
Contact Information
Telephone: 1 800 670 0707 (toll free North America) 1 360 925 5097 (direct)
Fax: |
1 360 925 5143 (direct) |
Email: customerservice@xantrex.com
Web: www.xantrex.com
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About This Guide
Purpose
The purpose of this Guide is to provide explanations and procedures for installing, configuring, operating, maintaining, and troubleshooting the Solar Charge Controller.
Scope
This Guide provides safety guidelines, detailed planning and setup information, procedures for installing the unit, as well as information about operating and troubleshooting the unit. It does not provide details about particular brands of photovoltaic (PV) panels. You need to consult individual PV manufacturers for this information.
Audience
This Guide does not provide sufficient information for anyone but a qualified installer to install this product. Installers should be electricians or technicians fully educated on the hazards of installing electrical equipment. The monitoring and operation information in this manual is intended for anyone who needs to operate the Solar Charge Controller.
Organization
This Guide is organized into five chapters and three appendices.
Chapter 1 describes features and functions of the Solar
Charge Controller.
Chapter 2 contains information and procedures to install the Solar Charge Controller.
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About This Guide
Chapter 3 contains information and procedures to configure the Solar Charge Controller.
Chapter 4 contains information about the operation of the Solar Charge Controller.
Chapter 5 contains information about identifying and resolving possible problems with systems using a Solar Charge Controller.
Appendix A provides the specifications for the Solar Charge Controller.
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 conditions or practices that could result in damage to the unit or to other equipment.
Important: These notes describe an important action item or an item that you must pay attention to.
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About This Guide
Abbreviations and Acronyms
AGM |
Absorbed Glass Mat |
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AWG |
American Wire Gauge |
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EMC |
Electro-Magnetic Compatibility |
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FCC |
Federal Communications Commission |
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Related Information
You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com.
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Important Safety Instructions
WARNING
This manual contains important safety instructions that should be followed during the installation and maintenance of this product. Be sure to read, understand, and save these safety instructions.
General Safety Instructions
•All electrical work must be done in accordance with local, national, and/or international electrical codes.
•Before installing or using this device, read all instructions and cautionary markings located in (or on) this guide, the unit, 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.
•To reduce the chance of short-circuits, use insulated tools when installing or working with the unit or any DC source (such as PV, hydro, wind, or batteries).
•Remove all jewelry when installing or working with the unit or any DC source. This will greatly reduce the chance of accidental exposure to live circuits.
•The unit contains more than one live circuit (batteries and PV array). Power may be present at more than one source.
•This product contains no user-serviceable parts.
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Safety
WARNING: Limitations on use
The Solar Charge Controller is not intended for use in connection with life support systems or other medical equipment or devices..
Battery Safety Information
WARNING
A battery can produce the following hazards to personal safety:
•electrical shock
•burn from high-short-circuit current
•fire or explosion from vented gasses.
Observe proper precautions when working with or around batteries.
•Always wear eye protection, such as safety glasses, when working with batteries.
•Remove all jewelry before working with batteries.
•Never work alone. Have someone assist you with the installation or be close enough to come to your aid when working with batteries.
•Always use proper lifting techniques when handling batteries.
•Always use identical types of batteries.
•Never install old or untested batteries. Check each battery’s date code or label to ensure age and type.
•Batteries should be installed in a well-vented area to prevent the possible buildup of explosive gasses. If the batteries are installed inside an enclosure, vent its highest point to the outdoors.
•When installing batteries, allow at least 1 inch of air space between batteries to promote cooling and ventilation.
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Safety
•NEVER smoke in the vicinity of a battery or generator.
•Always connect the batteries first, then connect the cables to the inverter or controller. This will greatly reduce the chance of spark in the vicinity of the batteries.
•Use insulated tools when working with batteries.
•When connecting batteries, always verify proper voltage and polarity.
•Do not short-circuit battery cables. Fire or explosion can occur.
•In the event of exposure to battery electrolyte, wash the area with soap and water. If acid enters the eyes, flood them with running cold water for at least 15 minutes and get immediate medical attention.
•Always recycle old batteries. Contact your local recycling center for proper disposal information.
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Contents
Important Safety Instructions- - - - - - - - - - - - - - - - - - - vii
1 Introduction
Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Maximum Power Point Tracking - - - - - - - - - - - - - - - - - - - - 1–3
Charge Controlling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Three-Stage Battery Charging- - - - - - - - - - - - - - - - - - - - 1–6
Bulk Stage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Absorption Stage - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Float Stage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
Two-Stage Battery Charging - - - - - - - - - - - - - - - - - - - - 1–8
No Float Stage - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8
Battery Temperature Compensation - - - - - - - - - - - - - - - - 1–8
Equalization Charging - - - - - - - - - - - - - - - - - - - - - - - - - 1–9
Auxiliary Output Functions - - - - - - - - - - - - - - - - - - - - - - - -1–10
Load Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–10
Vent Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–12
Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–12
Automatic PV Array Night Disconnect - - - - - - - - - - - - - - - -1–12
2 Installation
PV Array Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Array Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Array Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Array Current- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
MPPT Voltage Range - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Removing the Wiring Terminals Cover - - - - - - - - - - - - - 2–6
Removing Knockouts - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
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Contents
Mounting the Charge Controller - - - - - - - - - - - - - - - - - - 2–8 Grounding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9 Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–10 DC Terminal Connector Locations - - - - - - - - - - - - - - - -2–10 Wire Size and Over-current Protection Requirements - - - -2–10 Current Rating - - - - - - - - - - - - - - - - - - - - - - - - - - -2–11 Minimum Wire Gauge - - - - - - - - - - - - - - - - - - - - - -2–11 Over-current Protection - - - - - - - - - - - - - - - - - - - - -2–11 Long-distance wire runs - - - - - - - - - - - - - - - - - - - - -2–12 Maximum One-way Distance and Wire Size - - - - - - -2–12 Connecting the Charge Controller - - - - - - - - - - - - - - - - -2–14 Connecting Multiple Units- - - - - - - - - - - - - - - - - - - - - - - - -2–16 Aux Output Connections - - - - - - - - - - - - - - - - - - - - - - - - - -2–17 Network Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–17 Network Components - - - - - - - - - - - - - - - - - - - - - - - - -2–18 Ordering Network Components - - - - - - - - - - - - - - - -2–21 Network Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–21 Multi-Drop Backbone Layout - - - - - - - - - - - - - - - - -2–22 Daisy Chain Layout- - - - - - - - - - - - - - - - - - - - - - - -2–23 Guidelines for Routing the Network Cables - - - - - - - - - -2–25 Connecting Network Cable Between Multiple Units- - - - -2–25 Multi-Drop Backbone Layout - - - - - - - - - - - - - - - - -2–25 Daisy Chain Layout- - - - - - - - - - - - - - - - - - - - - - - -2–26
Installing the Battery Temperature Sensor - - - - - - - - - - - - - -2–27 Commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–29 Configuration Screens - - - - - - - - - - - - - - - - - - - - - - - - -2–29 Commissioning a Single Unit - - - - - - - - - - - - - - - - - - - -2–30 Commissioning Multiple Units - - - - - - - - - - - - - - - - - - -2–32
3 Configuration
Configuring the Charge Controller - - - - - - - - - - - - - - - - - - - 3–2
Configuration Menus - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Basic and Advanced Menus - - - - - - - - - - - - - - - - - - - - - 3–5
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Contents
Configuring Battery Characteristics and Battery Charging - - - 3–5 Setting a Custom Battery Type - - - - - - - - - - - - - - - - - - - 3–9 Battery Temperature Compensation - - - - - - - - - - - - - - - -3–11 Configuring Charge Controller Input - - - - - - - - - - - - - - - - - -3–12 Configuring the Auxiliary Output - - - - - - - - - - - - - - - - - - - -3–14 Trigger Source Descriptions - - - - - - - - - - - - - - - - - - - - -3–18 Trigger Source Configurable Ranges - - - - - - - - - - - - - - -3–20 Configuring the LCD - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–21 Device Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–23 Resetting to Factory Defaults - - - - - - - - - - - - - - - - - - - - - - -3–25
4 Operation
Viewing Operating Status - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
LCD Screens and What They Mean - - - - - - - - - - - - - - - - 4–2
Normal Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Charging States- - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6
Dynamic Text- - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7
Monitoring Charge Controller Operation - - - - - - - - - - - - - - - 4–9
Viewing Active Faults and Warnings - - - - - - - - - - - - - - -4–10
Viewing Logged System Data- - - - - - - - - - - - - - - - - - - -4–15
Daily Logs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–16
Monthly Logs- - - - - - - - - - - - - - - - - - - - - - - - - - - -4–17
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Contents
Battery Equalization - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–17
5 Troubleshooting
PV Charge Control Troubleshooting - - - - - - - - - - - - - - - - - - 5–1
A Specifications
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
Derating Curve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - A–3
Optional Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3
Regulatory Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3
B System Control Panel Menus
Using the System Control Panel II - - - - - - - - - - - - - - - - - - - B–2
System Control Panel Menu Map - - - - - - - - - - - - - - - - - B–3
Changing Settings Using the System Control Panel - - - - - B–5
Viewing the Select Device Menu- - - - - - - - - - - - - - - B–5
Viewing the Charge Controller Setup Menu - - - - - - - B–6
The Charge Controller Setup Menu - - - - - - - - - - - - - - - - - - - B–6
Configure Menu- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–8
Monitoring the Charge Controller - - - - - - - - - - - - - - - - - - - B–11
Charge Controller Home Screen - - - - - - - - - - - - - - - - - B–11
Meters Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–12
Index- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1
Warranty and Product Information - - - - - - - - - - - WA–1
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1 Introduction
Chapter 1 describes features and functions of the Solar Charge Controller.
For information on: |
See: |
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“Features” |
page 1–2 |
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“Maximum Power Point Tracking” |
page 1–3 |
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“Charge Controlling” |
page 1–5 |
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“Auxiliary Output Functions” |
page 1–10 |
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“Automatic PV Array Night Disconnect” |
page 1–12 |
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1–1
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Features
The Xantrex Solar Charge Controller is a photovoltaic (PV) charge controller that tracks the electrical maximum power point of a PV array to deliver the maximum available current for charging batteries. The Charge Controller can be used with 12-, 24-, 36-, 48-, and 60-volt DC battery systems.
The Solar Charge Controller is designed to regulate PV input only. It is not designed to work with wind or hydro generators.
The Charge Controller can be installed (in single or multiunit configurations) with a Xantrex XW Series Inverter Charger or in a stand-alone installation.
Figure 1-1 Charge Controller
Standard features of the Solar Charge Controller include:
•Twoor three-stage charging process, with manual equalization to maximize system performance and maintain expected battery life.
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Maximum Power Point Tracking
•Maximum Power Point Tracking (MPPT) to deliver the maximum available power from a PV array to a bank of batteries. See “Maximum Power Point Tracking” on page 1–3.
•Configurable auxiliary output. See “Auxiliary Output Functions” on page 1–10.
•Two-line, 16-character liquid crystal display (LCD) and four buttons for configuration and system monitoring.
•Input over-voltage and under-voltage protection, output over-current protection, and backfeed (reverse current) protection. Warning and Fault messages appear on the LCD when the unit shuts down as a protective measure.
•Over-temperature protection and power derating when output power and ambient temperature are high.
•Battery Temperature Sensor (BTS) to provide automatically temperature-compensated battery charging.
•Xanbus®-enabled. Xanbus is a network communications protocol developed by Xantrex. The Charge Controller is able to communicate its settings and activity to other Xanbus-enabled devices, such as the XW Series Inverter/ Charger, the System Control Panel II (SCP), XW Automatic Generator Start (XW-AGS), and other Xantrex XW-MPPT-60-150 Solar Charge Controllers.
•5-year limited warranty.
Maximum Power Point Tracking
Maximum Power Point Tracking allows the Charge Controller to harvest the maximum energy available from the PV array and deliver it to the batteries.
The MPPT algorithm continuously adjusts the operating points in an attempt to find the maximum power point of the array. The algorithm can then determine if it is harvesting more or less power than the previous operating points.
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The Charge Controller applies a variable load on the array— shown by the power curve (solid line) in Figure 1-2—until it finds the maximum wattage (the greatest number of amps per volt), as indicated by “MPP” in Figure 1-2. The Charge Controller then holds the array at this point for as long as the array continues to produce the required current. As panel shading, cloud cover, and sunlight angle shift, the Charge Controller finds the new maximum power point without interrupting its output power flow.
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(P) |
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/ Power |
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(I) Amps |
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Current |
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6 0 Vmp7 0 |
8 0 Voc 9 0 |
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Vo l t ag e |
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Figure 1-2 |
Maximum Power Point Curve |
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Charge Controlling
Charge Controlling
The Charge Controller can regulate PV array current at 12, 24, 36, 48 or 60 volts DC for charging batteries. It produces up to 3500 watts and 60 amps of charging current for all battery voltages except 60 V.
Figure 1-3 PV Charge Controller
The Charge Controller controls how the batteries are charged by the DC source (the PV array). It can be configured to use a two-stage (“No Float”) or three-stage charging process to maintain battery voltage at bulk or float levels.
When charging, the Charge Controller regulates the battery voltage and the output current based on the amount of DC power available from the PV array and the state of charge of the battery.
The Charge Controller is able to charge a lower nominalvoltage battery from a higher-nominal voltage array. For example, the Charge Controller can charge a 12-volt battery from a 36-volt array. This gives flexibility to installers to use longer wiring runs without compromising efficiency on a higher-voltage array.
The Charge Controller is not able to charge a higher-voltage battery from a lower-voltage array.
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Three-Stage Battery Charging
The three-stage charging process results in more efficient charging compared to on-off relay type or constant voltage solid-state regulators. The final float stage reduces battery gassing, minimizes electrolyte loss, and ensures complete battery recharging. Battery voltage and current vary during the three-stage charging process as shown in Figure 1-4 on page 1–7.
Bulk Stage
During the bulk stage, the Charge Controller sets its voltage limit to the bulk/absorption voltage setting. If the batteries are discharged, the Charge Controller operates in constant current mode, delivering its maximum current to the batteries. When the battery voltage reaches the Float voltage setting, the controller will transition to the absorption stage.
Absorption Stage
During the absorption stage, the Charge Controller continues to deliver its maximum available current output until the battery voltage reaches the bulk/absorption voltage setting. The Charge Controller then operates in constant voltage mode, holding the battery voltage at the bulk/absorption voltage setting for a pre-set time limit (the default time limit is four hours). During this time, current falls gradually as the battery capacity is reached. The Charge Controller transitions to the float stage if any one of three criteria are met:
1.The charge current allowed by the batteries falls below the exit current threshold, which is equal to 2% of battery capacity (for a 500 Ah battery bank, this would be 10 A), for one minute.
2.The battery voltage has been at or above the float voltage (which it reached during the bulk stage) for eight hours.
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SolarSurveyor_RevA.book Page 7 Friday, December 1, 2006 4:32 PM
Charge Controlling
3.The battery voltage has been at the bulk/absorption voltage setting for a pre-set time limit (the Absorb CV Time).
Float Stage
During the float stage, the voltage of the battery is held at the float 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 Exit to Bulk Voltage threshold for 1 minute, a new bulk cycle will be triggered.
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Absorption Stage |
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Figure 1-4 Three-stage Battery Charging Processa
a.An actual charging cycle for a PV-based system that is in use while it is being charged will likely differ from the cycle represented in Figure 1-4. This is because a PV system’s output is limited by the amount of solar energy available, and also because DC loads will affect the charge current and the measured battery voltage.
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SolarSurveyor_RevA.book Page 8 Friday, December 1, 2006 4:32 PM
Two-Stage Battery Charging
The two-stage charging process includes the bulk and absorption stages, but uses a “No Float” stage instead of “Float.” Two-stage charging is recommended for off-grid applications, where batteries are used more frequently and maintaining them at the float voltage is both less important and less practical. Two-stage charging can extend the life of most batteries.
No Float Stage
During the No Float stage the Charge Controller does not produce any charge current. Instead the Charge Controller monitors the battery voltage and transitions back to the bulk stage once the voltage drops below the Exit To Bulk Voltage setting for 1 minute.
Note: For more information about battery charging settings, see Table 3-2, “Battery Menu Values” on page 3–7 and Table 3-3, “Custom Battery Menu Values” on page 3–10.
Battery Temperature Compensation
The Battery Temperature Sensor (BTS) automatically adjusts the charging process of the Charge Controller. With the BTS installed, the Charge 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 protect it from over-charge or damage. Using the BTS can extend battery life and improve overall charging.
The BTS plugs into the BTS jack located inside the wiring compartment of the Charge Controller. The BTS can be installed on the negative battery post or on the side of the battery.
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SolarSurveyor_RevA.book Page 9 Friday, December 1, 2006 4:32 PM
Charge Controlling
Figure 1-5 Battery Temperature Sensor
If the BTS is not installed, the voltage settings for charging are based on one of three temperature settings (Cold, Warm, or Hot) available on the Charge Controller configuration menu. See “Configuring Battery Characteristics and Battery Charging” on page 3–5.
Equalization Charging
The Charge Controller can be used to provide the battery bank with an equalize charge.
Equalization is a deliberate overcharge designed to return each battery cell to optimum condition by reducing sulfation and stratification in the battery. The equalization charge is generally performed only on flooded, vented (non-sealed or “wet”) lead-acid batteries, as recommended by the battery manufacturer.
To avoid damaging your batteries, be sure to read all cautions and warnings concerning equalization charging. For more information, see “Battery Equalization” on page 4–17.
Important: The Charge Controller maximum output voltage is limited to 72 V for a 60 V battery system, which is the bulk voltage setting for 60 V batteries. Because of this output limit, the Charge Controller does not equalize 60 V batteries.
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SolarSurveyor_RevA.book Page 10 Friday, December 1, 2006 4:32 PM
Auxiliary Output Functions
The Charge Controller has a configurable auxiliary output (producing 5 to 13 volts at 200 mA) to drive a relay for load control or to turn on devices such as vent fans or indicator alarms. The auxiliary output can be configured to perform only one function at a time.
See “Configuring the Auxiliary Output” on page 3–14 for information about auxiliary output trigger sources and how to enable and configure the auxiliary output for your application.
CAUTION
The auxiliary output is intended only to energize a low-current circuit such as a relay coil. Connection to a high-amperage device will open the fuse in the common line and possibly damage the unit.
Load Control
The Charge Controller auxiliary output can be configured to drive a relay to disconnect or reconnect loads depending on battery voltage. This load control function enables the Charge Controller to help prevent damage to the battery from overdischarge during periods of poor charging (due to ambient temperature, for example) or excessive loads.
To use the Charge Controller to control loads and protect your batteries, you must connect the Charge Controller auxiliary output to a relay that controls a battery disconnect to disconnect the load from the batteries. The Charge Controller auxiliary output must be configured to activate when the batteries reach a pre-set voltage level.
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Auxiliary Output Functions
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Relay (200 mA)
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Figure 1-6 Load Control Wiring
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SolarSurveyor_RevA.book Page 12 Friday, December 1, 2006 4:32 PM
Vent Fan
The Charge Controller auxiliary output can be configured to power a small DC fan to clear a battery compartment of harmful gases. The Charge Controller auxiliary output must be configured to activate when the batteries reach their gassing voltage.
The auxiliary output can also power a small DC fan to cool the Charge Controller heat sink when the heat sink temperature rises above a pre-set temperature.
Alarms
The auxiliary output can be configured to trigger an alarm or indicator light when a pre-set condition occurs, such as low or high battery voltage, high PV array voltage, or a Charge Controller fault.
Automatic PV Array Night Disconnect
At night, or when the PV array voltage is less than the battery voltage, the Charge Controller opens an internal relay to prevent battery current from flowing back to the PV array. In this mode of operation the Charge Controller draws minimal power from the battery.
This automatic night-time disconnect eliminates the need for a blocking diode between the battery and the PV array. If the PV array consists of thin-film or amorphous solar modules, diodes may still be required to prevent damage during times of partial shading of the array. Check the documentation provided with the PV modules.
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2 Installation
Chapter 2 contains information and procedures to install the Solar Charge Controller.
For information on: |
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“PV Array Requirements” |
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“Mounting” |
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page 2–10 |
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“Installing the Battery Temperature Sensor” |
page 2–27 |
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“Commissioning” |
page 2–29 |
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PV Array Requirements
Note: The following information provides only general guidelines. The installation and rated performance of your PV array is subject to inspection and approval by the authority having jurisdiction.
Array Size
For PV array sizing guidelines, use the XW Solar Charge Controller PV array sizing tool accessible from www.xantrex.com/support.
Although the Solar Charge Controller can harvest a maximum of 3500 W, the PV array size can be as high as 6720 W (based on 48 A × 140 Vdc = 6720 W).
Array Voltage
CAUTION: Equipment damage
The PV array voltage must never exceed 150 Voc (open circuit voltage) under any conditions.
The maximum Vmpp (PV array voltage for Charge Controller MPPT operation) is 140 Vdc. The difference between Vmpp and Voc is shown in Figure 1-2 on page 1–4.
When calculating PV array size for the Solar Charge Controller you should consider the expected Voc of the array under all possible conditions. Panel voltage increases with decreasing temperature. The array needs to be sized so that the 150 Vdc does not occur, even at the lowest expected panel temperature during open circuit. The panel manufacturer provides a Voc rating per panel, but it is usually rated at 25 °C (77 °F). Ensure that the Voc rating at the coldest ambient temperature does not exceed 150 Vdc. A factor of 1.25 is applied to the rated Voc at 25 °C when the panel is colder than -21 °C.
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