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About load diversion:

 

The basic operating philosophy of a diversion controller is quite simple. Monitor the battery voltage, and if it should 
rise to a predetermined level, connect a diversion load or “Dummy Load”, of sufficient size, to the battery or energy 
source to prevent the battery voltage from increasing any further.  This is a very simple, yet very effective way of 
preventing battery overcharging. All alternate energy systems should have some form of battery overcharge 
protection.  

Several schools of thought on the subject.

 

1. 

The source of power (wind turbine, solar panels etc.) -- should remain connected to the batteries while the 
dump load controller is actively dumping the excess voltage.

 

2. 

The source should be diverted to the load directly and disconnected from the batteries.

 

We happen to believe that is far better to leave the wind turbine connected to the batteries at all times. Why? 
When you remove the battery from a wind turbine and send it's power directly to a load, then it sees for all 
practical purposes a short circuit (depending on the resistance of the load and lead wires.)  This may cause the 
turbine blades to slow dramatically and in some cases bring it to a halt. This braking action can cause heat 
build up in the stator if it is repeated every few seconds or so (if the battery is just a little over the top). When 
you allow the turbine to see the batteries, along with the load, the turbine remains more within its design 
realm 
-- always a good thing. 

 

 

Please note: this controller does not include a blocking diode or an A/C to D/C rectifier, as these are specific to your 
application. If you are using the controller with a DC turbine or solar panels, you may need to purchase a blocking 
diode.  A/C turbines require rectification from A/C to D/C.

  

 
 
FAQ: Do I need a diversion load for a wind turbine? 
 
Yes. 

Diversion controllers work by diverting excess energy from the wind turbine to a diversion or “dummy load”. 

This diversion allows the turbine to remain under a load at all times. A solar panel may be safely disconnected from 
the batteries, but an active wind turbine should never be disconnected from its load (battery/diversion load). When a 
wind turbine is not loaded, it can easily speed out of control in high wind events, which can lead to catastrophic failure 
of the turbine as well as the possibility of damage and injury to other property and people. 

It is very important that 

your turbine has a very reliable load at all times.  
 

Please see our FAQs located on our website, 

www.ColemanAir.us

 for more information on this subject and 

many others. 
 

 
Diversion Load Types 

 
A diversion load needs to be larger (by at least 10-20%), than the sum total of all your solar/wind/hydro charge 
sources combined that will be routed through the diversion load.  When the diversion load is too small, battery voltage 
may continue to rise even when the diversion is active. It is also important to use a load that is not likely to fail. Light 

Summary of Contents for C440-HVAD

Page 1: ...e managed through the user interface Relay on time can be controlled and set for diversion times up to several hours Upper and lower set points can both be set Automatic LCD back light dimming to save...

Page 2: ...ies to complete a full charge of the batteries The internal LED on the upper left of the large PCB board motherboard is lighted when the solenoid is engaged The red LED on the small daughter board is...

Page 3: ...3...

Page 4: ...select the current value and then press the up button to exit the menu For example To change the float set point of the controller Press the Enter Up Down or Scroll button on the front panel The Charg...

Page 5: ...mechanical controller that does have the ability to track multiple voltages and react accordingly Additional charging logic has also been added including such features as re bulking an absorb mode th...

Page 6: ...solid state controller and may allow the voltage to rise or fall further than optimal To alleviate this condition it is recommended that your charge source s not exceed the battery bank s amp hour ca...

Page 7: ...state of the solenoid of less than two seconds Given these settings the controller may turn on and off the solenoid several times per minute This is great if you want to keep the batteries as close to...

Page 8: ...n it is connected to the batteries The solar VOC reading will only be accurate when the solenoid is enabled Hint Run the test cycle to watch how the enable disable of the solenoid affects the solar vo...

Page 9: ...you may hear the solenoid s coil pull in as normal but see no difference in the solar amperage or solar voltage during the test This generally indicates the normally closed contacts of the solenoid ar...

Page 10: ...the batteries along with the load the turbine remains more within its design realm always a good thing Please note this controller does not include a blocking diode or an A C to D C rectifier as thes...

Page 11: ...designed specifically for 12 24 and 48 volt systems are by far a better choice A very acceptable diversion load is a power resistor These can be obtained via your Coleman Air dealer Various wattages a...

Page 12: ...use the front panel buttons and display When mounting vertically the inputs of the controller should always be oriented downwards with the vent upwards to ensure the unit is able dissipate any captiv...

Page 13: ...d the coil is active the solenoid s bottom contacts open and disconnect the electrical connection from the solar panels to your battery bank The wind hydro input is not switched disconnected and conne...

Page 14: ...ircuits but they may be no competition to a direct lighting hit Many of our controllers have survived direct lighting hits due to the internal protective circuits yet the connected equipment like mete...

Page 15: ...eries will be allowed to drop percentage based Once the batteries reach the upper trip point you have set the same trip point as the non EDM mode the controller will engage and disengage the solenoid...

Page 16: ...tandby current 1W 15W 3W Energy consumed by the electronics meters on solenoid on 1A 75A 5A Minimum float setting volts 12 0 24 48 Maximum float setting volts 24 48 96 Factory default float setting vo...

Page 17: ...witch can offer such a level of reliability For such systems our solid state controllers no relays or solenoids should be considered To replace the solenoid 1st ensure all power is removed from the un...

Page 18: ...ms should be designed for no more than 125 amps continuous current Higher voltage higher amperage systems will result in a lower life expectancy of the solenoid We recommend our solid state controller...

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