Xantrex C35 manual

ww w.x ant rex .c om Sma rt choice for pow er C- Se rie s Mult ifun ctio n DC C ontr olle r Ma nu al T y p e C3 5 C4 0 C6 0 Own er’ s Manual[...]

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C-Series Multifunction DC C ontroller Owner’ s Guide[...]

Abou t Xa ntr ex Xantre x T e chno logy In c. i s a worl d-le ading supplie r of a dvance d power ele ct ronic s and con trol s with produ cts from 50 watt mobi le un its to one MW ut il ity-s ca le syste ms for wind , sola r , batte rie s, fue l cells , microt urbines, a nd back up power appli c ati ons in both gri d-connect ed and st and- a lo ne[...]

ii i About This Gu ide Pu rpose The pur pose of this Guide is to provide expl a nati ons a nd proc e dures for in stallin g, oper ati ng, m aint a ining, and t rouble shooti ng t he C-S eries M ultif unction DC Contr oller . Sc ope Thi s Guide provid e s safet y gui deline s, deta iled planning a nd setup informati on, proc edures for ins talling t[...]

About T hi s Guide iv 975 -0004-01-02 Rev D Chap te r 2 c ont ains inf ormation a nd proc edur es to install C-Se ries Multif uncti on DC Controll e r . Chap te r 3 c ont ains inf ormation a bout the opera tion of a C-Se ries Multif uncti on DC Controll e r . Chap te r 4, “T r oubl eshootin g” conta ins inf ormati on about i dentif ying and r e[...]

A bou t T h is Guide 975-0004-01- 02 Rev D v Abbrev i at ions and Acr onyms R e l at ed In fo rmat ion Y ou c an find m ore infor matio n about Xantre x T echnolog y Inc . a s well as its pr oducts and ser vices at www . xant re x. com. A SC A u thor iz ed Servi ce Cent er BTS Batte ry T emperat ure Sensor CM C-S er i es Met er CM/R C-Series Meter [...]

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975-0004-01- 02 Rev D vi i Im portant Safety I nstructions Ge neral S afe ty In s truc t ions • Al l electri ca l wo rk mu s t be done in acco rdan c e wit h l ocal, nati ona l, a nd/or inter nationa l electr ica l codes. • B efore install ing or using this de vice, read a ll ins tructions and c a ut ionar y marki ngs locat e d in (or on) this [...]

Safety viii 975-0004-01- 02 Rev D B at tery Saf e ty In form at ion • Al way s w ear ey e pro tect io n, suc h as safet y g lasse s, w hen workin g with ba tt eries. • R emove all je welr y bef ore working with ba tte rie s. • Ne ver work a lon e. Have s omeone a ssis t you wi th the i nstalla ti on or be close e nou gh t o come to your a id [...]

Bat tery Safe ty Informa tion 975-0004-01- 02 Rev D ix CA UT ION: A batte ry can produc e th e foll owing hazards to pe rs onal safet y: • elec tri c al s hoc k, • burn from hig h-s hort -c i rcui t cu rren t, and/o r • fir e or explos ion from vente d gass es. Obse rve pr ope r pre cau tions when work ing with or aroun d bat t e rie s.[...]

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xi Im portant S afety In structions - - - - - - - - - - - - - - - - - - vii 1 Introduction Fe atur es - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 Op era ting Mo des - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 Cha rg e C ontr ol Mod e - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 [...]

Contents xii 975-0004-01-02 Rev D Automati c/Manua l Bat tery Equali z atio n (EQ) and Low Vol ta ge Reconnect (LVR) Jumper - - - - - - - - - - - - - - 21 Adj ustin g the C-Serie s Volta ge Setting s - - - - - - - - - - - - - - - - - 22 Se ttin g V olta ge P ara me te rs fo r C harg e Cont rol M ode - - - - - 2 2 Se ttin g V olta ge P ara me te rs [...]

Content s 975-0004-01- 02 Rev D xiii 3 Operat ion Ba sic Op era tion - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 4 LE D S ta tus Ind icat or - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 5 Charge Control or Diversion Cont rol Indi c atio ns (Green) - - 56 B link ing Gre en - - - - - - - - - - - - - - - - - - - [...]

Contents xiv 975-0004-01-02 Rev D Ba tter y Si zing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 6 Eq ual izat ion Char gin g - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 7 Equali z ati on Setpoint s (Non-Seale d Batter ies Only) - - - - - - 79 C Di ve rsi on Load s Di vers ion Lo ad T yp es - - - - - - - - -[...]

xv Figur e 1- 1 C-Se ries Multif uncti on DC Cha rge Cont rolle rs - - - - - - 2 Fig ure 1 -2 3-s tag e B att ery Ch ar ging Pro ce ss - - - - - - - - - - - - - - - 5 Fig ure 1 -3 PV Ch ar ge C o ntr oller - - - - - - - - - - - - - - - - - - - - - - - 7 Fig ure 1 -4 Di vers ion Co nt rol ler - - - - - - - - - - - - - - - - - - - - - - - - 9 Fig ure[...]

Fi g u r e s xv i 975 -0004-01-02 Rev D Fig ure 2 -22 A WG Wir e G aug e R ef erenc e C h art - - - - - - - - - - - - - 4 0 Fig ure 2 -23 PV Char g e Co ntr ol Mod e Wi rin g - - - - - - - - - - - - - - 45 Fig ure 2 -24 D ive rsi on Co nt rol M od e W ir ing - - - - - - - - - - - - - - - 47 Fig ure 2 -2 5 L oad Con tr ol Mod e W iri n g - - - - - -[...]

xv ii Tab le 2- 1 Fa ctor y Defau l t Setti n gs for C-S eri es Co n tro l lers - - - - 1 9 Table 2-2 Var ia nces in Charging Volta ge based on Ba tter y T emp era tur e - - - - - - - - - - - - - - - - - - - - - - - 3 5 Tab le 2 - 3 Mi ni mum W ir e S ize - - - - - - - - - - - - - - - - - - - - - - - 4 1 Tab le 2 - 4 O ne-W a y W ire Di sta nce an [...]

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1 Intr oduction Chapt er 1 des cribes featur es and func t ions of the C-Series Multifunction DC Controller . Fo r i nformatio n on: See: “Fea tur es” page 2 “Operat ing Modes ” page 3 “Control ler Fun ctions ” page 7 “Opt iona l A cc ess or i es ” page 12[...]

Int roduction 2 975 -0004-01-02 Rev D F eatu res The C35/ C40/ C60 ( C-Se r ie s ) controll e rs can be used with 12-vol t, 24-vol t, or 48-vo lt DC systems (depe nding upon mode l) a s Charge Contro ller or a Load Contr oll er . Numerous featu res are provi ded stand ard to maximize the pe rf orm an ce o f th e s y st e m: • S olid -stat e Pu ls[...]

Operating Modes 975-0004-01- 02 Rev D 3 • I ndoor -type, powder -coate d enclosure, for wa ll mountin g. • C onfor mal-coate d circuit bo ards, pl ated ter minals , powd er -coated meta l compone nts, and stainl e s s steel fa stene rs im prove s t olerance to host ile e nvi ronments. • M eets Na tional Ele ctri cal Code (NEC) and other inter[...]

Int roduction 4 975 -0004-01-02 Rev D Char g e Control Mode In the Cha rge C ontrol m o de, t he C-Ser ie s controls how the batt e rie s are char g ed by the DC source (sol a r , wind, or hyd ro). I t uses a 3- stage ch arging pr otocol t o maint a i n batte ry vol ta ge at bulk and/or floa t leve ls. Wh en ch a r gi ng, the C-S eri es c o ntrolle[...]

Operating Modes 975-0004-01- 02 Rev D 5 Bulk Stag e Du rin g this st age, the bat teri es ar e ch arged at the bu lk vo lta ge sett ing and maxim um curr ent out put o f the DC sour ce. Whe n t he ba tter y vo ltage reache s t he bulk volta ge se tti ng, the contr ol le r acti va t es th e next stage (ab sor ption). Abso rption S tage During this s[...]

Int roduction 6 975 -0004-01-02 Rev D Batter y T emperature C o mpensation The option a l Battery T emper at ure Sensor (BTS ) autom at ical ly adjusts the char ging process of the C- Ser ies contr ol ler . With t he B T S in s t a l l e d , th e C- S er ie s will incre ase or decr e ase the batt ery char ging voltage dependi ng on the t empera tur[...]

Controller F unctions 975-0004-01- 02 Rev D 7 Co ntroll er F un cti on s The C- Se r ie s can be configur ed to func tion as thr ee d iff e rent contr ol lers: • PV Cha rge Contr ol ler (Char g e Cont rol m ode) • Diversio n Controll er (Char ge Control mode) • Load Contro ller (Loa d Contr ol mode) Ph oto voltaic Ch arg e Co ntro ller The C [...]

Int roduction 8 975 -0004-01-02 Rev D If the curre nt from the PV array rea ches 85 amps, the contr ol le r will tur n of f to prot ect the ci rcui try . In the eve nt of a s hutdown, the c ontroll e r automati c ally res ets i tself a fter 10 mi nutes ( if over curre nt condi tion is no long er p resent) . Se e “Ope rati ng Mode Jumper ” on pa[...]

Controller F unctions 975-0004-01- 02 Rev D 9 Diver sion Loads Div ersion con trol r e qu ires a sepa rate “ dum p ” load t o r egul at e t he battery . This l oa d must be able to abso rb more power tha n t he c har ging sourc e is able t o produ c e at its pe ak o utput, or t he DC voltage will be come unregula ted. The dump load must be avai[...]

Int roduction 10 975 -0004-01-02 Rev D Loa d Contr olle r The C-Serie s contro ller ca n opera te as a Low V o lta ge Dis connect (L VD) f or DC lo ads to prevent ov er -disc harge to batt e rie s dur ing peri ods of poor char ging or exces sive loads. The C-Ser ie s contro ller uses the u ser -ad justa bl e setpoint s to dete r mine when to discon[...]

Controller F unctions 975-0004-01- 02 Rev D 11 or aut omatic reconne ct when the C-S er ie s is use d as a lo ad contr ol ler . Do n ot use thi s decal i f usi ng the C- S er ie s contr ol ler as a PV Char ge Contro ller or Diversi on Control ler . Low V olt ag e Disc o nnec t Wh e n con fi gur ed a s a l oad c ont r ol ler , th e C -S e ri es c on[...]

Int roduction 12 975 -0004-01-02 Rev D Op tio n al Ac ces so r ie s Th e f ollow a cce ssori es can be pu rc has ed f o r us e with the C-Se ries Multif uncti on DC Controll e r : • Di spl ay M et ers : The CM facepla te or CM/R remote di splay pr ovide a d igital dis play f or monit oring the C -S e ri es c on tr oll er ’ s oper ation. The CM [...]

2 Installation Chapt er 2 contains infor mation and pr ocedures to install C-Series Multifunction DC Controller . Fo r i nformati on o n : Se e: “Pre-Ins tall ation” page 14 “Mountin g the Con trol le r” page 16 “Configu ring the C-Ser ie s Cont rol ler” page 18 “Adj ustin g the C-Se ries V olt age Se ttings ” pag e 22 “Grounding [...]

Insta llation 14 975 -0004-01-02 Rev D Pr e- Inst al l atio n Th e inst ru ction s that fo llow are app l icab l e to the typic al i nstalla ti on. Fo r spe cial appli c ati ons, consul t a qua lifie d ele ctr ician or your Xantre x Certi f ied Deal er . In stalla ti on pro cedu re s wil l vary acco r d ing to you r sp eci fic ap p lic at ion. Rem [...]

Pre-Installation 975-0004-01- 02 Rev D 15 kno ckou ts before maki ng any wir ing conne ctions. It is also re commended t o use bushi ngs or condui ts to p r otect the wirin g from damage from rough edges in the knockout hole s. Fi gure 2- 2 C-Ser ies Dim ensions and Knock out Loc ation s (Not t o Scale) Side Vi ew Rear Vi ew 8" (203 mm ) 6 7/8[...]

Insta llation 16 975 -0004-01-02 Rev D Mo unting the Co nt rol ler The C-Serie s contro ller is design e d f or ind oor mounting . Care should be take n in selecti ng a locat ion and when mountin g the enclosur e. A void mounting it in direc t s unlig ht t o pre vent h e atin g of the enc losure. The enc losure s hould be mounte d verti c all y on [...]

Pre-Installation 975-0004-01- 02 Rev D 17 If us ing “seale d” ba tterie s, th e co ntrolle r c an be m ount ed in t he same enclosur e as long as it is adequa te ly ventil a t ed. W ARNING : Explosio n/Corr osion Haz ard Do no t lo c a t e th e C-Series c ont roller in a se aled com p a rtmen t with t he ba tte ri e s. Ba tt eri es can v ent hy[...]

Insta llation 18 975 -0004-01-02 Rev D Configuring the C- Seri es Cont ro ll er Befor e maki ng any wiring conne ctions to the C-Seri es contr ol ler , it must be configur ed for the desi red mode of oper ation. Th e f ollowi ng s ectio ns d escribe t he how to conf igure t he unit for t he de sire d appl ication a nd f unction. Jump er Se t ti n g[...]

Configuring the C- Series Controller 975-0004-01- 02 Rev D 19 T able 2-1 F ac tor y De f au l t Se t tin g s f o r C -Se r ie s Co n tr o ll ers Set t ing C35, C40 and C6 0 Bat te ry V oltag e 12 vo lts DC Equali ze/L VR Manua l E qu ali za tion O p erati ng Mode Ch ar ge Contro l Fi gure 2- 5 Cir cu it B o ard Co m pon en t s Oper atin g Mode Ju m[...]

Insta llation 20 975 -0004-01-02 Rev D Oper ating Mode J umper Th is jum per det er min es the o pera tin g mod e. P lace t he jum p er over t he pin s that correspo nd to t he de sire d mode . • Char ge Contr ol ( PV Char ge Cont rolle r or Di versi on Contr oll er) • Load Contr ol (L oa d Con tro ller) Facto r y defaul t setting is Char ge C [...]

Configuring the C- Series Controller 975-0004-01- 02 Rev D 21 Automatic /Manual Batter y Eq ualization (EQ) and Low V oltage Reconnect (L VR) J ump er Depe nding on the m ode of operatio n chosen, th is jumper enab les : • automat ic or manual b a ttery equaliz ation (Ch ar ge Contr ol mode), or • automat ic or manua l re conne ct in the event [...]

Insta llation 22 975 -0004-01-02 Rev D Ad jus ti ng t he C- Se ri es V ol ta ge S ett in gs The char ging voltage set point s and voltage rec onnect / di sco nnect setti ng of the cont ro ller are ad justable using two rota r y p otentiom eter co ntrols. The knobs are removabl e to re duc e the l ikeliho od of accide nta l mis-adjus tm ent if bumpe[...]

Adjus ting the C -Se ries Voltag e Se ttings 975-0004-01- 02 Rev D 23 For FL OA T ch arge v ol tag e, t he p ot ent iom eter s cale is ca libra ted f oll ows: • 12-vol t syste m: 12.5 to 14.5 vol ts i n in crements of 0.2 volts, • 24-vol t syste m: 25.0 to 29.0 vol ts i n in crements of 0.4 volts, a nd • 48-vol t syste m: 50.0 to 58.0 vol ts [...]

Insta llation 24 975 -0004-01-02 Rev D Sett i ng V ol tage P a ramet ers f or Load Co ntro l Mo de T o change the Low V olt ag e Disconne ct (L VD) and Low V oltag e R ec onnect (L VR) settin gs, use the same BULK and FLOA T po tentiom eters. Howeve r , w h en the C- Se r ie s contr ol ler is used for DC Load Control, the potenti om ete r ’ s sca[...]

Adjus ting the C -Se ries Voltag e Se ttings 975-0004-01- 02 Rev D 25 The scale fo r the Lo w V oltage Disc onnect setting is ca libra ted a s follows: • 12-vol t syste m: 10.5 to 12.5 vol ts i n in crements of 0.2 volts, • 24-vol t syste m: 21.0 to 25.0 vol ts i n in crements of 0.4 volts, a nd • 48-vol t syste m: 42.0 to 50.0 vol ts i n in [...]

Insta llation 26 975 -0004-01-02 Rev D Sett i n g V o lta ge P a ramet ers Di ve rsio n C ont rol Mode Wh en the C-S eri es c on tr oll er is config ured f or Diversion Contr ol mode, yo u can se t the v oltage at which t he uni t begin s diverti ng curren t t o a diversion load (hi gh v oltage di versi on). Use the Char ge Co n trol scale for sett[...]

Adjus ting the C -Se ries Voltag e Se ttings 975-0004-01- 02 Rev D 27 Fi gure 2- 14 V olt a ge Settings with R 46 Resist or Clipped CA UTIO N: Damage to Bat teries It is n ot re co m men d e d to al lo w an e q ua li z e c h arge to o cc ur if th e R4 6 R esist or is c l ippe d. High er cha r ging v olt ages may da mage t he batt e ri es. Ma ke sur[...]

Insta llation 28 975 -0004-01-02 Rev D Us ing a Digita l V o ltme ter to Ad just V oltag e Settin gs A di gital DC vol tmete r (DVM) can be used t o provide a mo r e ac curate sett ing of vol tage pa ramet ers. T est points a re provi de d at the mid-range on the sca les for this pur pose. The pote ntio m ete rs are equippe d with remo vable knobs [...]

Adjus ting the C -Se ries Voltag e Se ttings 975-0004-01- 02 Rev D 29 Fo r examp l e for a 48-vol t sys t em: T o set BULK voltage to 56.4 volts : 1. Point the BULK potenti omete r to the mid-ra nge positio n. 2. Adj ust the potentiom eter until the DVM displays 1.1 volts (1. 1 x 4 [48 volt] = 4.4 + 52.0 = 56. 4) . Fi gure 2- 15 T es t P oints f or[...]

Insta llation 30 975 -0004-01-02 Rev D Equa li za ti on C hargi n g The C- Se r ie s off e rs either ma nual or automatic tr igger ing of t he equal izat ion char ging process . Equa liz ation ch ar ging is t he delibe rat e process of char ging a batter y (or bat tery bank) at a high volta ge for a s et period of ti me to remix the elect rol yte a[...]

Equalization Charging 975-0004-01- 02 Rev D 31 Ma nua l Eq ualiza tion Manual e qualiz ation of the bat tery can be enabl ed by pressing t he Reset Swit ch on the rig ht side of the C-S eries un til the st at us LED indicato r begins to alte rnat e between red and gre en . This could ta ke about 10 seconds . The e qualiz ation pr ocess wi ll conti [...]

Insta llation 32 975 -0004-01-02 Rev D Aut oma tic Equal ization The C-Serie s contro ller ca n auto ma tica l ly trigg er an equa liza tion char ge ever y 30 days. The sta tus LED wi ll i ndicat e tha t the e qualiz ation proc ess i s occur ring. The equ ali zati on p rocess will c ontin ue until the volta ge has bee n held above t he bulk sett in[...]

T emp er atu r e C omp ens a ti o n 975-0004-01- 02 Rev D 33 T ermin at ing the E qualization P rocess T o stop the equa lization pr ocess, press the rese t switch on the right side of the uni t until the status LED stops alternat ing betwe en r ed a nd green. If the equal izat ion process wa s s horter tha n one hour , the contr ol le r will conti[...]

Insta llation 34 975 -0004-01-02 Rev D T emp er atur e Com pensat ion Ba sed on B atte ry T ype The C -Se ries c ont rol ler uses t he batt ery type to determine t he t emperatur e c ompensated voltage s e ttings . The te mpera ture comp ensate d char ging voltag e is normally ba sed on a Lea d – Acid type s of battery . If us ing Alkaline -type [...]

T emp er atu r e C omp ens a ti o n 975-0004-01- 02 Rev D 35 T able 2-2 V ariances i n C harging V oltage ba s ed on Battery T em per ature T emperat ure (ar ound the BTS) 12-vo lt units 24-vol t units 48-vol t units C e lsius F ahr enheit Lea d Aci d (6 cells) Ni Cad (10 cells ) Lead Aci d (12 c ells ) NiCad (2 0 c e ll s) Lead Aci d (24 cells ) N[...]

Insta llation 36 975 -0004-01-02 Rev D If us ing a BTS, when t he batter y t emperatur e d r ops be low 77°F (25 ° C), the regula ti on vo ltage sett ing aut omatica lly i ncreases. When the t empera ture r ises above 77°F (25 °C) the re gulation battery voltage s e tting automati call y dec reases. Man u al Ba tt er y T e mp e rat u re Co mp e[...]

Grounding 975-0004-01- 02 Rev D 37 Grounding The C-Serie s contro ller is design e d to work wi th b oth nega tive ground and unground e d ele ctric al syste ms. The met al chassis of this c har ge/load c ontroller must be g r ou nded for eit he r syst em by conne cting it with a copper wire t o a ground ing e l ectr ode such as a ground rod driven[...]

Insta llation 38 975 -0004-01-02 Rev D Wi r i n g D C T erm inal C onn ector Locat ions T ermi nal conne ctor s for DC wiring are locate d on the lower edge of the circ uit boar d. See Figur e 2-21 . The common nega tive s can be reverse d or wire d with an appr opr iate ly size d si ngle conducto r to a m o re conv enient loc ation s uch as a DC l[...]

Wi ri ng 975-0004-01- 02 Rev D 39 T erminal T orq ue Requir ements On ce the wire s hav e b een ins tal le d, torqu e the ter mi nal s a s foll ows. Be careful not t o over tigh ten. • 20 inc h-pounds for # 14-10 A WG wire • 25 inch- pounds for # 8 A WG wire • 35 inch- pounds for # 6 A WG wire Wire Si z e an d Ov er - c ur re nt Pro t ec t i [...]

Insta llation 40 975 -0004-01-02 Rev D Mi nimum R ecommended W ir e G au ge The mini mum recommende d wire gauge is: • C35 and C40 Mode ls: #8 A W G with a 75 °C (167 °F) ins ulation r ating • C60 Models : #6 A W G , with a 90 °C (194 °F) ins ulation r ating The te rmina ls on the C- Ser ies will accept up to #2 A WG (33. 6 mm 2 ) c opper o[...]

Wi ri ng 975-0004-01- 02 Rev D 41 contr ol ler are str ongly r ecommende d. Put a surge prote ction devic e on the input line of t he C -S eri es c ont r oll er bet ween t he PV array and the cont rolle r . If the batte ry , is over 15 feet a way from the c ontr oll er , or if it i s rout ed next to other wiring or s ources of power , a dd itio na [...]

Insta llation 42 975 -0004-01-02 Rev D Long-dis tance wire runs If the re is a signi fican t dis tan ce bet ween t he PV array and the contr ol le r an d/or the controll e r and the bat te ry , lar ger wires ca n be used to r educ e the vo ltage drop a nd im prove perfo r ma nce. R efer to T able 2- 4 . T o use a lar ge r size wi re, use a splic er[...]

Wi ri ng 975-0004-01- 02 Rev D 43 T able 2-4 One- W ay Wir e Dista nce a nd Wire Size Maximum One-way W ire Distanc e for a < 3% V o ltage dro p 12 Vdc Applicat io n Sho wn Fo r 24 Vdc Sy stem s , Multiply d ist ance by 2 Fo r 48 Vdc Sy stem s , Multiply d ist ance by 4 Distan ce in F e et (me ters) Distance in Fee t (Mete rs) a a.T hese wire si[...]

Insta llation 44 975 -0004-01-02 Rev D PV Ch ar g e Contro l Mode W iring The pro cedur e below is ill ustra ted in Figure 2-23 . T o c onn ect th e C-S eri es con tr oll er a s a c harg e con troller: 1. Conne ct the PV ar ra y’ s posi tive (+) output to the PV ar ray disc onnec t. 2. Route anot her (+) cabl e fro m the other end of the RE di sc[...]

Wi ri ng 975-0004-01- 02 Rev D 45 Fi gure 2- 23 PV Char ge Control Mode W irin g 4 2 1 7 5 6 8 A 3 9 A Batter y Po si t i ve (+ ) PV + A r r ay Posit i ve ( +) PV A rray Negati ve (–) Batter y Nega ti ve ( –) Common N e gat ives Ensure the pr oper grou nding is in place fo r the enti re syst em.[...]

Insta llation 46 975 -0004-01-02 Rev D Dive rsion Cont r ol Mode W iring The pro cedur e below is ill ustra ted in Figure 2-24 . Wh en usi n g the C-S eri es unit a s a Di versi on or DC Loa d Contr oll e r , the DC load needs to be conne ct ed to the con tro ller t erm in als m arked as PV +/ LOAD + and CO MMON NE GA TIV E . T o c onn ect th e C-S[...]

Wi ri ng 975-0004-01- 02 Rev D 47 Fi gure 2- 24 Diversio n Contr ol Mode W iring 4 2 1 7 5 6 8 A 3 Ensu re th e prope r gro undi ng i s i n place f or th e enti r e syst em. A Batter y Positi ve ( +) Dive rsi on L oad Posit i ve ( +) Diver s ion L oad Negati ve (– ) Batter y Nega ti ve ( –) Co m mon Negativ es[...]

Insta llation 48 975 -0004-01-02 Rev D D C Load C o ntr o l Mode W iring The pro cedur e below is ill ustra ted in Figure 2-25 . T o c onn ect th e C- Ser ie s co n tr ol ler as a D C l oad cont roll er: 1. Conne ct a ca ble f rom the BAT POS ITI VE termina l on t he contr ol le r to a batte r y disconne ct. 2. Conne ct the positive battery c able [...]

Wi ri ng 975-0004-01- 02 Rev D 49 Fi gure 2- 25 Load Contr ol Mode Wirin g 4 2 1 5 3 Batter y P osi ti ve ( +) D C Loa d Posit i ve ( +) DC Load Neg ative ( –) Ba tter y Nega ti ve (– ) Co m mon Negati ves[...]

Insta llation 50 975 -0004-01-02 Rev D Ins tal li ng Opt iona l Acce ss orie s The fol lowing sections descr ibe how to inst all the opt ional acc ess o ries ava ilabl e for the C-S erie s Mul tifunc tion DC Contr oll er . Ins talling a Digita l Display Follo w the inst ructi ons in the C-Se ri es M ete r Displa ys Inst a l lat ion Guide for pr epa[...]

Inst alling O pt iona l Acc essori es 975-0004-01- 02 Rev D 51 Ins tal ling the B att ery T empe r atur e Sensor T o instal l the BTS: 1. Inst a l l the BTS on t he side of the batte r y below the elect rol yte l eve l. It is bes t t o p lace th e se nso r bet ween batt e ries a nd pl a ce the batte ries in an i nsulated box to re duc e the i nflue[...]

Insta llation 52 975 -0004-01-02 Rev D R ei nst alli ng t he F ac epl ate T o reins tall t he face pl ace o n t he C -S eri es cont rolle r : 1. Ali gn fac eplat e with front of chas sis so that scre w hole s i n the corner s line up. 2. Inse rt the phi llip s s crews i nto the scre w hol es a nd t ighten. Fi gure 2- 28 Re-installing the C M F acep[...]

3 Op era tio n Chapt er 3 contains infor mation about the operation of a C-Series Multifunction DC Controller . Fo r I nformat io n o n: See: “Basic Operat ion ” page 54 “LED St at us Indic ator” page 55 “Char ge Co ntrol o r Di ver sion Cont rol Indicat io ns (Green)” page 56 “Load Con trol Indic ation s (Red)” page 58 “Error Mod[...]

Operat ion 54 975 -0004-01-02 Rev D B as ic Op er at ion The C-Serie s contro ller (a ll models) ha s one multic olor LED st atus indicator a nd one r ese t bu tton. Fi gure 3- 1 C-Ser ies Stat us L E D and Re s et Button Location Mult i colo r LED indi cator Rese t Switch Rese t Switch (on s i d e o f uni t)[...]

LED St atu s In di ca to r 975-0004-01- 02 Rev D 55 LED St at us Ind i cat o r The mult ic olor LED on the base unit, or the optiona l CM fa cepla te or CM/R remote, ind icates the o perating stat us of t he controll er . A color -c oded label is included on the cover of t he contr oller expl a i ning the status LED’ s indication s. • When i n [...]

Operat ion 56 975 -0004-01-02 Rev D Cha rg e Con trol or Dive rsion Contr ol Indicatio ns (G reen ) Th e f lashin g r at e of t he L ED i ndica te s t he c o ntroll er ’ s s tag e of ope rati on and appro ximate battery volt a ge. • One to four flas hes in dica t es the contr oller is in th e Bul k sta ge. As th e f las hing r at e in cr eases [...]

LED St atu s In di ca to r 975-0004-01- 02 Rev D 57 For exampl e, if the s ystem batte ry volta ge is 24 volt s and the i nternal B ulk v oltage se tt ing is set for 28 vo lts, y ou ca n esti m ate how m uch be low t he Bulk setting the batte ri es are by subt rac ting th e number i n Ta b l e 3 - 1 (th e interna l Bulk sett ing). W ith the LED i n[...]

Operat ion 58 975 -0004-01-02 Rev D Equal ization Mode I ndication (Red/gr een) Be sure to read all cauti ons a nd warning rega r ding equa liz ation c har gin g batt e rie s BEFORE allowing an equa liza tion char ge to oc cur . Da mage t o batt e rie s can occur . Al te rna ti ng R ed and G re en The c ontr oller is in th e EQUALIZE mode. It will [...]

LED St atu s In di ca to r 975-0004-01- 02 Rev D 59 Err or Mode Indica tion (Or ang e) The C-Serie s Multifu nction DC Contro ller er ro r m od es i ncl ude the following . • Over - t empe rature Condit ion - fast fl ash • Over - cur r ent Condit ion - fas t flash • Low-V oltage Disc onne ct Condit ion (Load Contr ol Mode) - sl ow flash Over [...]

Operat ion 60 975 -0004-01-02 Rev D F as t B linking Orange When the over - c urr ent or over -t e mpera ture pr otect ion syste m has c ause d t he c ontrolle r t o shutdown, the s tatus L ED will be ora nge and will bli nk fast ( about once a secon d). Low-vo ltage Disconnec t Condition If volta ge remains bel ow t he L VD setting , the unit will[...]

Re s et Sw it ch 975-0004-01- 02 Rev D 61 Re se t Sw it ch Use the Reset Switc h o n the side of the chass is for the foll owing c o nditi ons. • T o ma nuall y initi ate bat tery e quali zatio n in C har ge Contr ol mode, press and hold the Reset Swi tch until the re d and green LED start to f lash. • T o ma nuall y suspend ba ttery e qual iza[...]

62[...]

4 T r oubl eshoot ing Chapter 4, “ T roubles hoot ing” contains information about identifying and resolving possible problems with systems using a C-Seri e s Multif unc tion DC Contro ller . Fo r I nformat io n o n: See : “PV C har ge Cont rol T roubles ho oting” page 64 “Div ersio n C ontr ol Tr oubl eshoo ti ng” pa ge 66 “Load Con t[...]

T roubleshooting 64 975 -0004-01-02 Rev D PV Ch arg e C ont r ol T roubles hooti ng The fol lowing table list s possibl e proble ms th at m ay aris e when using the C -Ser ies Multi funct ion DC Controlle r as a PV C har ge C ontrol ler . T able 4-1 PV Cha r ge Cont rol Problem s Pr obl em P os sib le C au se S ol uti o n Cont r o ll er is over cha[...]

PV C harge Control T roubleshooting 975-0004-01- 02 Rev D 65 Current une ve n betwee n m u lt ip l e co n tr o l le r s . A. Solar array s are supp lying dif feren t amo unts of curr ent to ea ch c h arge c on tr oll er . B. Cha rging s et point s a re no t all s et the s am e. C. E xces s volt ag e drop i n wirin g causi ng c ont roll er s to m ea[...]

T roubleshooting 66 975 -0004-01-02 Rev D Div ersion C ontrol T roubl es hootin g The fol lowing table list s possibl e proble ms th at m ay aris e when using the C -Ser ies Multi funct ion DC Controlle r as a Div ersio n Contr oll er . T able 4-2 Diversion C ontrol Pr oblems Pr obl em P os sib le C au se S ol uti o n St at us L ED Bli nks Orange a[...]

Diversion Control T roubleshooting 975-0004-01- 02 Rev D 67 Divers ion lo ad operat es while a generator (fu el power ed) is runni ng. Bu lk V olt age se tt ing on di ve rs ion co ntrol ler is se t too cl os e to other c har g er s ett in gs. A . Bulk vo ltage on control le r need s to be se t high er t ha n o the r ch ar ging sources or use a s w [...]

T roubleshooting 68 975 -0004-01-02 Rev D Load Cont r o l T roubl eshoot ing The fol lowing table list s possibl e proble ms th at m ay aris e when using the C -Ser ies Multi funct ion DC Controlle r as a Load Cont ro ller . T able 4-3 Load Control Prob lems Pr obl em P os sib le C au se S ol uti o n Load dis co nne cts at dif fe ren t point t ha n[...]

A S pecifi cations Appendix A, “Specifications” provide the specif ications for the C -Series Multif unction DC Control ler . Fo r i nformatio n on: See: “Ele ctric al Speci ficat ions” pa g e 70 “Featu res and Opt ions Specifi c a ti ons” page 71 “Envir onm ent al Spe cif icat ions” page 72[...]

Specif icat ions 70 975 -0004-01-02 Rev D El ect ric a l Sp ecif i cat ion s Th e follo w in g lists the el ectri ca l spe cifi cat io n s for the C -S e ri es c on tr oll er s Models C35, C40, and C60. T able A-1 E lectrical Specifications Model C 35 C40 C60 V o lta ge Conf igur ati o n 1 2 Vdc 2 4 Vdc 12 Vdc 2 4 Vdc 48 Vdc 12 Vdc 2 4 Vdc Maximum [...]

F e ature s and Optio ns Sp ecific ation s 975-0004-01- 02 Rev D 71 F ea t ur es an d O pti on s Sp eci fica tio ns The f ol lowing lis ts the f eature s a nd opti ons s pecific ation s for th e C -Se ri es c ont rol ler s M odels C35, C40, and C60. Load C ontr ol Set t i ngs: System V o ltag e: Low V o ltag e Reconn ect Low V o ltag e Disc onn ect[...]

Specif icat ions 72 975 -0004-01-02 Rev D Env i r o nm ent al S pec i fic a tio n s The fol lowing lists the enviro nmenta l speci ficatio ns for the C -S e ri es c on tr oll er s Models C35, C40, and C60. T able A-3 E nvironmental Specifications Model C35 C40 C 60 E nclo su re T ype In doo r , ven tilate d , po wde r-coa ted ste el w ith 3 /4 &quo[...]

B Bat teries Appendix B, “Batteries ” descr ibes types of batteri es. Fo r i nformatio n on: See: “Batt ery T ypes” pag e 74 “ B atte r y Si zi n g” pa ge 7 6 “Equal izat ion Ch ar gi ng” page 77[...]

Bat terie s 74 975 -0004-01-02 Rev D Ba tt er y T y pe s Bat teri es c ome i n di ff er ent si z es, t ype s , amp- hour c apacit y , vol ta ges and chemistr ies. Here are a few guideli nes that will help in ba ttery s e lec tion , and ensur e th a t the batte ries ar e prope r ly main taine d. The be st so ur ce of the most approp riat e sett ings[...]

Ba tt er y Typ es 975-0004-01- 02 Rev D 75 V ented bat te ries usu ally have bat t e ry caps . The caps may appe ar to be s ealed, but are not. The caps should be removed peri od icall y t o ch ec k t he leve l o f elect rol yte . W hen a c ell is l ow , dist illed wat er should be added after t he batter y is full y cha r ged. If the level is ext [...]

Bat terie s 76 975 -0004-01-02 Rev D N iCad and N i F e Batteries The Xant rex C-Ser ies is compa tibl e with NiCad (nic ke l-c admium) NiFe (nic kel -iro n) and alka li ne-t ype batt e ries, whi ch mus t b e ch ar ged t o a h igher vol tage leve l t o achi eve a full charg e. T o use t he C-Ser ies wi th NiCad ba tt eries, c lip the wire on the re[...]

Equalization Charging 975-0004-01- 02 Rev D 77 Equa li za ti on C hargi n g Approxi m ate ly ever y month, som e batte ries may need to be “e qualiz ed.” S ince the individua l cells of the batt ery are no t i dent ical , some cells may not be ful ly char g e d when the cha rgi ng process is co mpleted. If th e ba tter ies ha ve b e en left i n[...]

Bat terie s 78 975 -0004-01-02 Rev D CA UTIO N: Damage to Bat teries Equa liz atio n shou ld be don e onl y on ve nt ed (not seal ed or mainte na nce-free) l ead -acid, liqu i d-ele ctroly te ba tt eries. The batt e ry manufactur er should be consul ted before at te m pting to equa lize any othe r batte ry type . Add clea n, distil led wa te r to t[...]

Equalization Charging 975-0004-01- 02 Rev D 79 Eq ualizat ion S etpoint s (Non -Sealed Ba t ter ies O nly) T able B- 1 T ypical Bulk and Float Setpo ints for Batter ies B a ttery T ype Bulk V olt s Float V o lts Eq uali zing Cha r ge Default Se tti ngs (knobs at nine o’c loc k posit ion) 14 .0 Vdc 13.5 Vdc Dis a bled (manual jumpe r) Seal ed Ge l[...]

80[...]

C Diver sion Loads Appendix C, “Diversion L oads” provides additional information about Diversion Loads. Fo r i nformatio n on: See: “Div ersio n L oad T ypes ” page 82[...]

Diversion Loads 82 975 -0004-01-02 Rev D Div ersi on L o ad T y pe s Sev era l diff er ent types of diver sion loads are ava ilable to the alt ernat ive e n er gy ma rk et. The se l oads a re des igne d to oper a te with the power outp ut level s common to most di versi on l oad c ontroll e rs. Th e followi ng are se veral ava ila ble div e rsi on [...]

D iv ersion Load T ypes 975-0004-01- 02 Rev D 83 Regar dle ss of t he ty pe of di version load y ou de c ide t o utili z e, make su re th at the diversion load c an hand le all the power the cha r gi ng s ystem is capable of putting out. Parall eling heate r ele ments ( whethe r open air or water heat er) will allow more power d issip ation. A good[...]

84[...]

85 W a rr anty and Pr oduct In formatio n Wa r r a n t y What does thi s warr ant y cove r? This Li mi t ed W arr anty i s pr ovided b y Xa ntre x T echno logy , Inc . ( "Xa ntrex ") and cove rs defe cts in wor km an shi p an d m a te rial s in your C- Se ries Mult ifunc tion DC Co ntrol le r . T h is war ra n ty per io d la st s fo r two[...]

W ar ranty an d Prod uct I nf orma tio n 86 975 -0004-01-02 Rev D Di re ct ret ur ns m ay be p er f or m ed ac cor ding t o the Xa nt rex Retu rn Mat eria l Aut horiz at ion Po licy des cribe d i n you r prod uct manu al. Fo r s ome pr odu cts, Xant rex m aint ains a ne twor k o f re gional Auth or ize d Ser vice Cen te rs . Call Xan tr ex or che c[...]

Retu r n Mate ria l A utho riza t ion P ol i cy 975-0004-01- 02 Rev D 87 P AR T ICULAR PU RPOSE TO THE EXT ENT REQ UIRED UNDER APPLICA BLE LA W TO APPL Y TO THE PRODUCT SHALL BE LIMITED IN DURA TION TO T HE PERIOD STIPULA TED UNDE R T HIS LIMITED W ARRANTY . IN NO EVENT W ILL XANTR EX BE LIABLE FOR ANY SPECIAL, DIR ECT , INDIRECT , INCIDENT AL OR C[...]

W ar ranty an d Prod uct I nf orma tio n 88 975 -0004-01-02 Rev D Return Proce dure 1 . Pa ckage t he un it saf ely , pre fera bly usi ng t h e or igi nal box and pa cking mat e r ia ls . Pl ea se ensu re that your produc t is shi pped ful l y ins ured in t h e ori gin al pack aging or e qui valen t. This warran ty wi ll not appl y wher e t h e pro[...]

Information About Y our System 975-0004-01- 02 Rev D 89 Inf orm atio n Ab out Y our Sys tem As s oon a s you op en you r C-S er ie s M ult i f unc tion DC Cont roll er pack age, r ecord t he f ol lowing inf orma tion an d be su re to kee p your pro of of pur cha se. I f you need to conta ct Cu st omer S e rv ic e, p lease rec ord t he f ol lowi ng [...]

90[...]

Acce ssor ie s 12 Aut om atic E qual iz at ion 32 Batt ery Sa fety I nforma tion viii Ba tt ery T emper atu r e Co m pe nsat ion 6 Batt ery T e mper a t ure S ensor 12 , 51 BULK cha r ge vol ta ge 22 Ch ar ge C ontro l or D i ve rs ion Cont rol Mod e Indi c atio ns 59 Cu st om er S er v ice prepari ng to c a ll 89 Di versi on Control Mode 8 , 26 EQ[...]

Index 92 975 -0004-01-02 Rev D Re set Swit ch 59 Safet y I nstructi ons v ii se rial num ber 89 T e st P oin ts f or V oltag e S e tt ing s 28 T orque R e qu irements 39 T roubls hoo ti ng 6 4 V o l ta g e Ju mp er 20 warran ty out of warrant y servi c e 88 terms and condi ti ons 85 W ir e Si ze 3 9 W iring 38 Xantre x web site v[...]

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Xantrex Technology Inc . 1 800 670 0707 Tel toll fr ee NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct c usto mers er vi ce@ xa n trex .c om ww w.xantr ex.com 975-0004-01-02 Pri n ted in China[...]