Xantrex Technology C35, C60, C40 User Manual
Smart choice for power
e
C35
C40
C60
Owner’s Manual
C-Series Multifunction DC Controller
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, bat teries, fuel cells, microturbines, and
backup power applica tions in both grid-connected and stand-alone systems.
Xantrex products include inverters, battery chargers, programmable power
supplies, an d variable speed drives that conve rt, supply, control, cl ean, and
distrib u t e el ec tr i cal power.
Trademarks
C-Series Multifunction DC Controller is a trademark of Xantrex International.
Xantrex is a registe red trademark of Xantrex Internat ional.
Other trademarks, registered trademarks, and product names are the property of
their respecti ve owners and are used herein for identification purposes only.
Notice of Copyright
C-Series Mul tif unctio n DC C ontr oll er Own er’s Gui de © No vembe r 200 3 Xantrex
International. All rig hts 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) ASSUMES 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 Revisi on D
Part Number
975-0004-01-02 Rev D
Contact Information
Telephone: 1 800 670 0707 (toll free North Americ a)
1 360 925 5097 (direct)
Fax: 1 800 994 7828 (toll free North Americ a)
1 360 925 5143 (direct)
Email: customerservice@xantrex.com
Web: www.xantrex.com
About This Guide
Purpose
The purpose of this Guide is to provide explanations and
procedures for insta lling, operating, maintai ning, 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 about ope rating and troubleshooting the
unit. It does not provide details about particular brands of
batteries. You need to consult individual battery
manufacturers for this information.
Audience
This Guide is intended for anyone who needs to install and
operate the C-Ser ies Multifunction DC Controller . Installers
should be certified technicians or electricians.
Organization
This Guide is organized into four chapters and three
appendices.
Chapter 1 describes featur es and functions of the C-Series
Multifunction DC Controller.
iii
About This Guide
Chapter 2 contains infor mation and procedures to install
C-Series Multifunction DC Controlle r.
Chapter 3 contains infor mation about the operation of a
C-Series Multifunction DC Controlle r.
Chapter 4, “Troubleshooting” contains information about
identifying and resolving possible problems with systems
using a C-Series Multifunc tion DC Controller .
Appendix A, “Specifications” provide the specifications for
the C-Series Multifunc tion DC Controller .
Appendix B, “Batteries” describes types of batteries.
Appendix C, “Diversion 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 ide ntify conditions or practices that could result in
damage to the unit or to other equipment.
Important:
an item that you must pay attention to.
iv 975-0004-01-02 Rev D
These notes describe an important action ite m or
Abbreviations and Acronyms
ASC Authorized Service Center
BTS Battery Temperature Sensor
CM C-Series Meter
CM/R C-Series Meter - Remote
DC Dir ect Cur rent
LCD Liquid Crystal Displa y
LED Light Emitting Diode
LVD Low Voltage Disconnect
LVR Low Volta g e Reconnect
RE Renewable Energy
Related Information
You can find more information about Xantrex Technology
Inc. as well as its products and servic es at
www.xantrex.com.
About This Guide
975-0004-01-02 Rev D v
vi
Important Safety Instructions
WARNING
This manual contains important safety instructions that should be
followed during the installa tion and mainten ance of this product . Be
sur e to read, understand, and save these s afety instructions.
General Safety Instructions
• All electrica l work mus t be don e in acco rdan c e wit h
local, national, a nd/or international electr ic al codes.
• Before install ing or using this de vice, read all ins tructions
and cautionary marki ngs located in (or on) this guide , the
controller, the batteries, PV array , a nd 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 installa tions, the C-Series controller must be
installed i n a ra inproof enclosu re t o elim inate e xposu re to
rain or water-spray.
• T o 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 jewelry. This will greatly reduce the chance
of accidental exposur e to liv e circuits.
• The controller 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 jewelry befor e working with ba tteries.
• 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 iden ti cal typ es of ba tter ie s.
• Never install old or unt ested batteries. Check each
battery’s date code or label to ensure age and type.
• Batteries shou ld be installed in a well-vented area to
prevent the possible buildup of explosive gasses. If the
batteries ar e installe d ins ide an enclosu re, vent its h ighest
point to the outdoors.
• When installing bat teries, allow at least 1 inch of air
space between batteries to promote cooling and
ventilation.
• NEVER smoke in the vicinity of a battery or generator.
• Always connect the batteries first, then connect the
cables to the inverter or controller. This will greatly
reduce the chance of spark in the vicinity of the batteries.
• Use insulated tool s when working with batteries.
• When connecting batteries, always verify proper voltage
and polarity.
• Do not short-circu it 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 atte ntion.
• Always recycle old batteries. Contact your local
recycling cen ter fo r p rop er disp o sal info rm at ion.
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-ci rcuit current, and/or
• fire or explosion from ve nted gasses.
Observe proper prec autions when working with or around 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-S tag e Bat tery 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
Low Voltage Disconnect - - - - - - - - - - - - - - - - - - - - - 11
Low Voltage Reconnect- - - - - - - - - - - - - - - - - - - - - - 11
Optional Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
- - - - - - - - - - - - - - - - - - v ii
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-Series Volta ge 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 Adjus t Voltage Settings- - - - - 28
Equalization Charging- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
Manual Equalization - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
Automatic Equalization - - - - - - - - - - - - - - - - - - - - - - - - - 32
Terminat ing the E q ual izat i on Process - - - - - - - - - - - - - - - 33
Temperature Compensation - - - - - - - - - - - - - - - - - - - - - - - - - 33
Temperature Compensation Base d 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-current Prote c tion Requirements- - - - - 39
Current Rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39
Minimum Recommended Wire Gauge - - - - - - - - - - - - 40
Surge Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
Over-current Protection - - - - - - - - - - - - - - - - - - - - - - 41
Long-distance wire runs- - - - - - - - - - - - - - - - - - - - - - 42
Maxim um O n e-way D istan c e an d Wire Size - - - - - - - - 42
PV Charge Control Mode Wiring - - - - - - - - - - - - - - - - - - 44
Diversion Control Mode Wiring - - - - - - - - - - - - - - - - - - - 46
DC Load Con trol Mo d e Wi 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-temperature Condition - - - - - - - - - - - - - - - - - - - 59
Over-Current Condition- - - - - - - - - - - - - - - - - - - - - - 59
Low-voltage Disconnect Condition - - - - - - - - - - - - - - 60
Reconnecting to Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
Reset Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
4
Troubleshooting
PV Charge Control Troubleshooting - - - - - - - - - - - - - - - - - - - 64
Diversion Control Trouble shooting - - - - - - - - - - - - - - - - - - - - 66
Load Control Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - 68
Contents
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 Syste m - - - - - - - - - - - - - - - - - - - - - 89
Index
xiv 975-0004-01-02 Rev D
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91
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 - C M/R, CM, and BTS- - - - - - - 12
Figure 2-1 Removing the Front Cover - - - - - - - - - - - - - - - - - - - 14
Figure 2-2 C-Series Dimensions and Knoc kout 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 Ci rc uit Board Co m po ne nts - - - - - - - - - - - - - - - - - - - 19
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 Bulk and Float Charge Pote ntiometers (pots)- - - - - - - 22
Figure 2-10 Bulk and Float Charge Settings for Charge/Div ersion
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 2-19 Terminating the E qu al izat i on Charge - - - - - - - - - - - - 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 2-25 Load Control Mo d e Wi ri ng - - - - - - - - - - - - - - - - - - 49
Figure 2-26 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- Series Front Pane 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 g s for C-S eri es Co nt ro lle rs- - - - 19
Table 2-2 Variances in Charging Voltage 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 provi ded standard to maximize the
performance of th e system:
• Solid-state Pulse Width Modulated (PWM) charging
process with thre e-st ag e con tr ol, temp era tur e
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 reset capability increases the
reliability of unattended systems by eliminating blown
fuses and tripped circu it brea kers.
• 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-coate d metal components, and stainless steel
fasteners improves tolerance to hostile environments.
• Meets National Elect rical Code (NEC) and other
internation al co ntr o ller speci fications.
• The C35, C40 a nd C60 models are UL listed to the
U.S. UL Standard 1741 (1s t edition), and Canada
(CSA-C22.2 No. 107.1-95).
• 2-year limited warr an ty.
Operating Modes
The DC controller is a critical component in any solar, wind
or hydro power generation syst em and protects the batteries
from over-di scharge and over-charge conditions. The
C-Series has two operating modes (Charge Control mode and
Load Control mode determined by the Operat ing mode
jumper (See Figure 2-5). These two different operating
modes allow the C-Series to be instal led and f unction a s thr ee
different DC contr ollers.
• Cha rge Control Mode
• PV Charge Controller - contr ols 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.
Operating Modes
• Load Control Mode
• Load Contr oller - prevents damage to the battery from
over-disc harge during periods of poor char ging or
excessive loa ds.
975-0004-01-02 Rev D 3
Introduction
Important:
than one function at the same time. If several functions ar e
requi r e d in a syst em, a dedi cated c ontroller must be used for each
function.
The C-Series controller cannot operate in more
Charge Control Mode
In the Charge Control mode, the C-Series controls how the
batteries are char ged by the DC source (solar , wind, or
hydro). It us es a 3-stage char ging protocol t o maint ain ba tter y
voltage at bulk and/or float le vels.
When charging, the C-Series controller monitors the ba tt eries
and depending on how it is wired wil l regu late the PV c urrent
(as a PV Charge Controller) or divert e xcess energy 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-sta ge charging of battery voltag e,
• 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 voltage setting reduces battery gassin g, mini mize s
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 current vary dur ing the three-stage charging
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 sourc e. When
the battery voltage reaches the bulk voltage setting, the
controller acti vates the next stage (absorption).
Absorption Stage
During this stage, the volta ge of the batte ry is held a t the bulk
voltage setting until an internal timer has accumulated one
hour. Current gradually decline s as the battery capacity is
reached.
Float Stage
During this sta ge, the vol tage of t he batt ery i s held at the floa t
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 for
a cumulative period of one hour, a new bulk cycle will be
triggered.
Operating Modes
Charging
Started
DC Voltage
0 volts
DC Current
0 amps
Time
Figure 1-2
Bulk Stage
Increasing Voltage Constant Voltage Reduced Vol tage
Max Amps
Constant Current Reducing Current Reduced Current
3-stage Battery Charging Process
Absorption Stage
Bulk Volts Setting
Absorption Time
Float Stage
Float Volts Setting
975-0004-01-02 Rev D 5
Introduction
Battery Temperature Compensation
The optional Battery Temperature Sensor (BTS)
automatically adj usts the charging process of the C-Series
controller. With the BT S in stalled, th e C-Series will increase
or decrease the battery charging voltage depending on the
temperature of the batt ery to optim ize 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 temperatur e of the
environment around the batteries and on the type of batteries
being used.
See “T e mperature Compensation” on page 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 pro vide the battery bank with an equalize
charge. Factory default setting is for MANUAL Equalization
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 loa d or loads from the system when an
over-disc harge or over-l oad situation occurs. The C-Series
controller uses the user-adjustable setpoints to determine
when to connect or reconnect loads depending on battery
voltage. A load controller prevents damage to the battery
from over-di scharge during periods of poor weather or
excessive loa ds. The u nit does not charge the batteri es when
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 m ode)
Photovoltaic Charge Controller
The C-Series cont roller can operate as a Photovoltaic Charge
Controller, also called a “series regulator” . De pending on the
model, the controller can regulate up to 60 amps of
continuous photovolta ic (PV) array current at 12 or 24 volts
(C60 or C35 mode ls), or 12-, 24- or 48-volts DC (C40 model)
for charging bat teries. This rating includes the NEC required
derating.
Controller Functions
Figure 1-3
975-0004-01-02 Rev D 7
PV Charge Controller
If the PV array’s output increases above the rated amp level
due to reflecti on or “edge of cloud effect,” the controller will
continue to operate until the heatsink reaches a maximum
safe operating temper ature. This will take several minutes to
occur, depending upon the ambient temperatur e involved.
When the heats in k re aches the max imu m saf e tem perature,
the controller will reduc e the current, cooling the transis tors
and the heatsink.
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 minutes (if overcurrent condition is no longer present).
See “Operating Mode Ju mper” 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 disc onnected from the battery at night to
prevent reverse leakage of power. This eliminates the need
for a blocking diode between the bat tery a nd the PV array. If
thin-film or amorphous sola r modules are being used, diodes
may still be required to prevent damage from partial shading
conditions.
Check the documentation provide d with the PV modules.
Diversion Controller
The C-Series controller can operate as a Diversion Controller ,
also called a shunt regula tor , to manage battery charg ing from
alternative energy sources such as PV, wind or hydroelectric
generators. A diversion controller monitors batte ry 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 excess powe r genera ted from over-charging the
batteries. This allows the charging sour ce to remain under
constant load to pr event an over-speed condit ion which c ould
occur if the chargi ng source is suddenly disconnected from
the battery–as serie s regulators do.
Consult your dealer for recomme ndations on diversion load
type and regulator size .
8 975-0004-01-02 Rev D
Controller Functions
Figure 1-4
Diversion Controller
Diversion Loads
Diversion contr ol requir es a separ ate “dump ” load to 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 unregulate d. The dump load
must be available for the diversion of power at all times.
Resistive-ty pe heating elements are the best diversion loads.
Special direct -c u rrent w ater h eat in g elem en ts are av aila b le.
Light bulbs and motors are not recommended as diversion
loads because they are unreli able. A diversion load that dr aws
about 25% more current than the charging source’ s maximum
output capability is usually suitable for use with the C-Series
controller.
See Appendix C, “Diversion Loads” for additional
information on types of diver sion 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 ener gy expert.
Important:
to prev ent back fe ed .
CAUTION: Damage to Batteries
Current draw of th e diver sion l oad i s very im portant . Prob lems m ay
arise from operating with a load that is too small or too large. A
diversion load that is too small will not be able to abs o r b all the
exces s power from the current source once the ba tteries are full
allowing batteries to overcharge.
Diversion loads in excess of the controller’s rating are capable of
absorbing more power than the C-Series controller is designed to
handle, res ult ing in an over -curr ent shut down. Dur ing thi s ti me, the
unit will not regulate electrica l flow in the system and battery
damage may result.
Load Controller
The C-Series controller can operate as a Low Voltage
Disconnect (LVD) for DC loads to prevent over-discharge to
batteries during pe riods of poor charging or excessive loads.
The C-Series controlle r uses the user-adjustable setpoints to
determine when to disconnect or reconnect loads depending
on battery voltage.
If PV arrays are used with diversion control, it
If using multiple RE sources, use diodes/isolation
When used as a DC load controller, the settings of the LVR
and LVD are controll ed by two rotary potentiometers (also
called pots) on the circuit board.
The scale on the adjustment potentiometers differ from the
scale used for other functions. A decal with the appropriate
adjustment scale is include d with the C-Series. To apply the
decal, gently pull off the knobs of the potentiometers and
place this decal on the circuit board. After the decal is in
place, replace the knobs. The EQ jumper deter mines manual
10 975-0004-01-02 Rev D
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