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Inspectors generally insist that a breaker or disconnect be located as close to the energy source as possible and may
also insist on a 2
nd
breaker or disconnect near its final termination point. Please consult NEC regulations and your
local inspector to determine the requirements in your area. These subjects are outside of the scope of this manual;
however, it is your responsibility to ensure your unit is installed safely!
Solar panels and Wind/Hydro turbines are energy sources. A breaker or fuse is required between these devices and
any other components (including the HVAD). Do not hook up a wire from any energy source into the HVAD
without the ability to quickly and safely disconnect the input. All inputs need fuses or breakers!
Wiring the controller.
Please refer to the large hookup diagram at the beginning of this manual.
The positive wire from the battery (which is routed through a breaker) is connected to the left most bottom terminal.
Please remove the nut and washer and place your wire terminal under the washer but above the large red wire that is
already present.
The solar panels connect to the 2
nd
terminal from the left (through a breaker of course.).
The wind/hydro energy source connects to the 3
rd
terminal from the left (via a breaker).
The three terminals on the far right are shared negatives. Connect at least one large wire from one of these terminals
to the negative post (or buss) of your battery bank. Solar and hydro negative leads can be wired here as well;
however, it is generally better to wire them directly to the negative post (or buss) of the battery bank.
As mentioned above, when the solenoid is not enabled, the solar input is electrically connected via the normally
closed (connected) contacts of the solenoid, to the positive post (buss) of your battery bank. This means that the solar
positive is hooked directly to your battery positive during the idle state of the solenoid. When the solenoid is engaged
(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 connected) by the solenoid. This input is always connected
directly to your battery bank. The only electrical reason this input is provided at the controller is for monitoring
purposes. As the current passes though the controller (and the turbine shunt located on the upper right of the
controller), the microprocessor is able to determine the current flow of your turbine. This input also passes though the
breaker on the right side of the unit. This breaker allows the turbine input to be disconnected for diagnostic purposes,
but again, this does not fulfill the requirement of having an over-current protection device between the turbine and the
controller.
The diversion load (real or dummy) if used, must be hooked to the middle two terminals on the left side of the unit.
Most resistive devices (heaters) are not polarity sensitive; so in this case, it does not matter which terminal is wired to
which input of the load. Other loads, such as inverters, pumps, power supplies etc, are polarity sensitive and must be
hooked up with the correctly polarity. The upper terminal (of these two terminals) is the positive connection. This is
the terminal that has the aluminum strap connected to it that crosses over the top of the solenoid. The lower terminal
is the negative terminal for your load and is electrically connected to the three terminals on the lower left of the
controllers. The normally open contacts of the solenoid (the two that stick out the sides of the solenoid), are used to
control the diversion load. The diversion load is enabled (connected to the battery) when the solenoid is enabled.
No diversion load is required for a solar only installation. When the batteries reach the trip point, the solar energy
will be disconnected from the batteries until the batteries drop. Diversion loads can however be used with solar only
installations and/or solar/hydro combined installations when the excess energy is desired to run “real” loads. In this
Summary of Contents for C440-HVAD
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