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Xantrex Trace C Series, Installation And Operation Manual

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Xantrex Trace C Series Installation And Operation Manual Download Page 23

©2000 Xantrex Technology Inc.

PV Array

BATTERY

PO

PV +/

LOAD +

COMMON

NEGATIVES

CONTROLLER

PV CHARGE CONTROL

MODE

PV +

PV -

B

BATTERY -

Circuit Breaker

Circuit Breaker

3553-W01-00A

–

+

BATTERY

Figure 6

PV Charge Control Wiring Diagram

17

3.0 INSTALLATION

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Summary of Contents for Trace C Series

Page 1: ...Installation and Operation Guide C Series Multifunction DC Controllers 2000 Xantrex Technology Inc P N 975 0004 01 01 Rev B 11 00 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 2: ... 2000 Xantrex Technology Inc All manuals and user guides at all guides com ...

Page 3: ... Load Control Indications Solid Red Blinking Red Slowing Blinking Orange Equalization Mode Indication Alternating Red and Green Error Mode Indication Fast Blinking Orange 3 INSTALLATION 10 Mounting Wiring Minimum Recommended Wire Size Maximum One way Distance and Wire Size PV Charge Control Mode Cabling Diversion Control Mode Cabling DC Load Control Mode Cabling Grounding Configuring the C Series ...

Page 4: ...Series LCD Meter Displays Installing the DVM C40 Mounting the CM R 5 OPERATION 38 Three Stage Battery Charging Bulk Absorption Float Equalization 6 BATTERIES 41 Automotive Batteries Maintenance Free Batteries Deep Cycle Batteries Sealed Batteries NiCad and NiFe Batteries Battery Sizing 8 DIVERSION LOADS 43 Charge Controller Load Controller Diversion Charge Controller Diversion Load Types 9 SPECIFI...

Page 5: ...s de près NOTE This statement is important Follow instructions closely NOTE Cette déclaration est importante Suivre les instructions de près 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 the manual the inverter the controller the batteries...

Page 6: ...teries 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 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...

Page 7: ...o 107 1 95 Electronic overload and short circuit protection with automatic and manual reset capability increases the reliability of unattended systems by eliminating blown fuses and tripped circuit breakers Field adjustment of charge setpoints is provided by rotary controls with removable knobs reducing the potential for setpoint tampering Calibrated scales and test points allow precise adjustment...

Page 8: ...o enable the Photovoltaic Charge Control Mode see Configuring the C Series in the installation section of this manual If the PV array s output increases above the rated amp level due to reflection or edge of cloud effect the controller will continue to operate until the heatsink reaches a maximum safe operating temperature This will take several minutes to occur depending upon the ambient temperat...

Page 9: ...tage with temperature compensation and auto matic or manual equalization See the Three Stage Battery Charging section for more information on this process Diversion mode requires a separate dump load to regulate the battery This load must be able to absorb more power than the charging source is able to produce at its peak output or the DC voltage will become unregulated The dump load must be avail...

Page 10: ...voltage reconnect LVR setting for 6 minutes The EQUALIZE jumper determines manual or automatic reconnect when the C Series is used as a load controller When used as a DC load controller the settings of the LVR and LVD are controlled by two rotary potentiometers on the circuit board The scale on the adjustment potentiometers differ from the scale used for other functions A decal with the appropriat...

Page 11: ...stor switches are opened stopping the flow of electricity The detection circuitry is faster than breakers or fuses and they will not trip or blow when a fault occurs When the over current protection system is activated the status LED will indicate orange and will blink fast about once a second This is the same indication as produced by an over temperature condition The C Series controllers automat...

Page 12: ...d for the temperature of the battery during operation Seasonal adjustment of the setpoints may be necessary to prevent battery damage and to ensure proper charging If the battery temperature sensor is installed no seasonal adjustments are required see Temperature Compensation in this manual If the wiring to the sensor is damaged and the wires are shorted or cut the system will return to the non te...

Page 13: ...ge Load Controller Orange Blink Slow Load Disconnected Overload Overtemp Orange Blink Fast Multicolor LED Indicator Table 2 Battery Voltage LED Indications Figure 1 C Series Front Panel Label r o t a c i d n I s u t a t S D E L g n i s U E G A T L O V Y R E T T A B e d o M n o i s r e v i D e g r a h C D E L n e e r G D E L S U T A T S e d o M l o r t n o C d a o L D E L d e R g n i t t e S T A O ...

Page 14: ...e 2 on the previous page to determine the battery voltage NOTE A single green flash indicates the battery is below the bulk voltage setting It does NOT indicate the batteries are charging Load Control Indications Solid Red The controller is in the DC LOAD CONTROL mode and the battery voltage has reached the Low Voltage Disconnect LVD setting After a 6 minute delay DC loads will be disconnected unl...

Page 15: ...stops alternating red and green Error Mode Indication Fast Blinking Orange The controller detected an over current or an over temperature condition and the loads are disconnected The controller will try to automatically restart the loads after a 6 minute delay If the controller will not restart turn off all loads and press the reset switch If it then restarts the loads may be too large A delay up ...

Page 16: ... the upper two screw locations on the wall The back of the enclosure is provided with keyholes for mounting Leave the screw heads backed out approximately 1 4 inch 6 mm or less Place the controller onto the screws and pull it down into the keyhole slots Then insert the two lower screws to lock the enclosure onto the wall Provide either strain relief clamps or conduit to prevent damage to the circu...

Page 17: ...mpartment with the batteries Batteries can vent hydrogen sulfide gas which is corrosive to electronic equipment Batteries also generate hydrogen and oxygen gas that can explode when exposed to a spark If using sealed batteries the controller can be mounted in the same enclosure as long as it is adequately ventilated All manuals and user guides at all guides com ...

Page 18: ...20 inch pounds for 14 10 AWG 25 for 8 AWG 35 for 6 AWG once the wires have been installed Replace the cover 3 0 INSTALLATION 12 Figure 3 Voltage Selection Jumper Battery Positive PV Load Common Negatives Figure 4 Battery Connection Terminals NOTE Regardless of configuration only the positive conductor from a PV array OR a DC load may be connected to the terminal marked PV POS LOAD 12 Volt Position...

Page 19: ...G W A 8 s p m a 0 5 0 6 C e r i w C 0 9 G W A 6 y t u d 0 0 1 d e t s i l s p m a 0 6 0 6 C e r i w C 5 7 G W A 4 y t u d 0 0 1 d e t s i l s p m a 0 6 Table 3 Minimum Wire Size NOTE To meet UL requirements use 6 AWG 90 C wire and a 60 amp LISTED 100 DUTY over current device for the C60 controller Not approved by UL for direct connection into the controller Use a splicer block as specified below a...

Page 20: ... from the C Series controller to your load on the same line then read the wire size required at the top of the column The wiring over current protection devices fuses and circuit breakers and installation methods used must conform to all national and local electrical codes requirements Wiring should be protected from physical damage with conduit or a strain relief clamp You should pull the tempera...

Page 21: ... f 3 4 4 m 0 5 3 1 t f 0 6 5 m 7 0 7 1 t f 3 0 7 m 3 4 1 2 t f 6 8 8 m 1 0 7 2 t f 2 1 4 1 m 4 0 3 4 8 1 t f 9 4 m 9 4 1 t f 8 7 m 8 3 2 t f 4 2 1 m 8 7 3 t f 6 9 1 m 7 9 5 t f 2 1 3 m 1 5 9 t f 4 9 3 m 1 0 2 1 t f 8 9 4 m 8 1 5 1 t f 5 2 6 m 5 0 9 1 t f 7 8 7 m 9 9 3 2 t f 5 5 2 1 m 5 2 8 3 0 2 t f 4 4 m 4 3 1 t f 7 m 3 1 2 t f 1 1 1 m 8 3 3 t f 6 7 1 m 6 3 5 t f 0 8 2 m 3 5 8 t f 4 5 3 m 9 7 0 1...

Page 22: ...bottom of C Series s circuit board and tighten the lugs Connect the PV array s negative output to the terminal marked COMMON NEGATIVES and tighten the lugs Connect the battery positive cable to the terminal marked BAT POS and tighten the lugs Connect the negative battery cable to the terminal marked COMMON NEGATIVES and tighten the lugs Secure the cabling with strain reliefs after allowing a littl...

Page 23: ...OSITIVE PV LOAD COMMON NEGATIVES CONTROLLER PV CHARGE CONTROL MODE PV PV BATTERY BATTERY Circuit Breaker Circuit Breaker 3553 W01 00A BATTERY Figure 6 PV Charge Control Wiring Diagram 17 3 0 INSTALLATION All manuals and user guides at all guides com ...

Page 24: ...m the negative battery terminal to the terminal marked COMMON NEGATIVES on the controller s circuit board Connect a cable from the controller s terminal marked PV POS LOAD to the positive terminal of your DC diversion load Connect a cable from the controller s terminal marked COMMON NEGA TIVES to the negative terminal of your DC diversion load Tighten the terminal lugs to 20 inch pounds for 14 10 ...

Page 25: ...VE PV LOAD COMMON NEGATIVES CONTROLLER LOAD DIVERSION MODE PV PV BATTERY BATTERY Circuit Breaker Circuit Breaker 3553 W02 00A BATTERY DIVERSION LOAD Figure 8 Load Diversion Wiring Diagram 19 3 0 INSTALLATION All manuals and user guides at all guides com ...

Page 26: ... NEGATIVES Connect a cable between the PV POS LOAD terminal on the controller and the positive terminal on the DC load Connect a cable between the controller s COMMON NEGATIVES terminal and to the negative terminal of the load Battery Positive Battery Negative DC Load Positive DC Load Negative Figure 9 Load Control Wiring 20 3 0 INSTALLATION All manuals and user guides at all guides com a l l g u ...

Page 27: ...1 BATTERY POSITIVE PV LOAD COMMON NEGATIVES CONTROLLER DC LOAD CONTROL MODE BATTERY BATTERY Circuit Breaker BATTERY DC LOAD _ LOAD LOAD Circuit Breaker 3553 W03 00A Figure 10 Load Control Wiring Diagram All manuals and user guides at all guides com ...

Page 28: ...st be grounded for either system by connecting it with a copper wire to a grounding electrode such as a ground rod driven into the earth If a negative ground system is desired connect the negative current carrying conductor to the grounding system at one point in the system Consult local and national electrical codes for more information and any additional requirements All manuals and user guides ...

Page 29: ...equipped with several of these jumpers Each are discussed in the appropriate section of this manual The factory default settings are shown below 0 4 C 0 6 C 5 3 C e g a t l o V y r e t t a B C D s t l o v 2 1 C D s t l o v 2 1 R V L e z i l a u q E l a u n a M n o i t a z i l a u q E l a u n a M n o i t a z i l a u q E e d o M g n i t a r e p O l o r t n o C e g r a h C l o r t n o C e g r a h C T...

Page 30: ...ogy Inc Figure 12 Configuration Jumpers Location EQ LVR JUMPER CHARGE LOAD CONTROL JUMPER RESET SWITCH SYSTEM VOLTAGE JUMPER 24 3 0 INSTALLATION NICAD SETTING SELECTION RESISTOR All manuals and user guides at all guides com ...

Page 31: ...perating mode PV Charge Control and Diversion Control mode or Load Control mode Factory setting is Charge Control mode Reset Switch Press and hold to manually initiate or suspend battery equalization in Charge Control mode Press and release to reset following an error condition Press and release to reconnect following a low voltage disconnect event If voltage remains below the LVD setting the unit...

Page 32: ...0 and 55 VDC for the C35 and C60 If the optional LCD meter DVM C40 or CM R is attached to the C Series controller be sure to set the jumper on the back of it for the appropriate system voltage The jumper for limiting power consumption and dimming the CM display is also located on the back of the LCD Displays 3 0 INSTALLATION 26 Figure 16 Voltage Selection Jumper 12 Volt Position 24 Volt Position 1...

Page 33: ... circuit board for more information regarding bulk and float charging rates see the Three Stage Battery Charging Process section of this manual The potentiometer scale for bulk charge voltage is calibrated from 13 0 to 15 0 volts when the voltage jumper is set for a 12 volt system in increments of 0 2 volts from 26 0 to 30 0 volts 24 volt system in increments of 0 4 volts or from 52 0 to 60 0 volt...

Page 34: ... example to set the bulk voltage to 14 4 volts adjust the potentiometer until the DVM displays 1 4 volts 13 0 V 1 4 V 14 4 V To set bulk to 28 2 adjust the pot until the DVM displays 1 10 volts 1 10 x 2 24 volt 2 2 26 0 28 2 When using NiCad type batteries add another 2 12 volt 4 24 volt or 8 48 volts to the settings If you are using the unit as a DC load controller be sure to set the potentiomete...

Page 35: ...ays holding the voltage 1 volt for 12 volt systems 2 volts for 24 volt systems and 4 volts for 48 volt systems above the bulk setting for 2 hours During the equalization process the status LED indicates equalization by alternately blinking green and red Equalization is not recommended for NiCad batteries and is disabled when the R46 resistor is cut 3 0 INSTALLATION 29 Figure 21 Equalization Settin...

Page 36: ...anual Equalization Manual equalization of the battery can be enabled by pressing the reset switch on the right side of the C Series for 10 seconds The status LED indicator will begin to alternate between red and green once equalization is enabled The equalization process will continue until the batteries have been held at or above the bulk setting for two hours of accumulated time During the equal...

Page 37: ...the AUTO setting The default setting of the C Series controllers is for manual equalization To disable the automatic equalization system move the equalize jumper To manually stop the equalization process press the reset switch on the right side of the unit until the status LED stops alternating between red and green If the equalization process was shorter than one hour the controller will continue...

Page 38: ...ures above 80 F 27 C and raised for ambient temperature below 75 F 23 C If significant seasonal variations are common you will have to change the settings several times a year to prevent battery damage and ensure proper operation NOTE Do NOT compensate the settings when using the C Series controller as a DC load controller Table 6 Temperature Compensation Temperature compensation is based on batte...

Page 39: ...LK setting when in Charge Control mode subtract 1 volt for 12 volt systems 2 volts for 24 volt systems and 4 volts for 48 volt systems From the scale shown for the LVD setting FLOAT setting in Charge Control mode subtract 2 volts for the 12 volt system 4 volts for a 24 volt system and 8 volts for a 48 volt system Figure 24 DC Load Control Adjustment Sticker MANUAL reconnect of the loads is allowed...

Page 40: ...wo blinks the battery voltage is approximately 24 5 volts 26 volts Bulk setting minus 1 50 volts in the table With the LED indicating one blink the battery voltage is somewhere below the 24 5 volts indicating the battery may be seriously damaged NOTE The LED will light green only in Diversion and Charge Control mode unless it is reinstalled backwards Table 7 Battery Voltage LED Indications r o t a...

Page 41: ...d Status LED green red or orange If the C Series controller is disconnected from the battery or the meter cable the meter will be reset when it is powered up Press and hold the push button on the front of the meter to manually reset the amp hour meter Press and release this button to turn the backlight on or off An adjustable potentiometer on the back of the meter enables you to adjust the contras...

Page 42: ...he LED that you just removed Align the faceplate and reinstall the screws If the LED must be replaced in the future it will operate in either orientation except if replaced incorrectly the color of the status LED will be reversed The connecting cable for the display is a six conductor telephone cable with modular type connectors RJ15 Although any telephone type cable will work the cables provided ...

Page 43: ...ed with relief behind it and it can be located up to 1000 feet 305 meters from the C Series controller itself If the CMR appears inaccurate or unusual on runs over 100 feet from the controller remove the jumper located below the voltage configuration pins on the back of the CM R This dims the LCD backlight reduces power consumption and improves meter accuracy All manuals and user guides at all gui...

Page 44: ...tting until an internal timer has accumulated one hour Current gradually declines as the battery capacity is reached During the ABSORPTION stage the status LED green blinks five times then pauses and repeats FLOAT During this 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 ar...

Page 45: ... t l o V C D s t l o v 2 1 s t l o v 4 2 s t l o v 8 4 Table 9 Typical Setpoints for Batteries S E I R E T T A B R O F S T N I O P T E S T A O L F D N A K L U B L A C I P Y T e p y T y r e t t a B s t l o V k l u B s t l o V t a o l F s s e c o r P e g r a h C g n i z i l a u q E s g n i t t e S t l u a f e D n o i t i s o p k c o l c o e n i n t a s b o n k C D V 0 4 1 C D V 5 3 1 r e p m u j l a...

Page 46: ...tes an imbalance exists If the battery construction prevents measurement of the individual cell voltages use a hydrometer A variation of 0 020 in the specific gravity between cells is considered significant Both conditions can be corrected by an equalization charge A proper equalization charge will not damage a vented liquid electrolyte type battery It may however cause significant electrolyte usa...

Page 47: ...id electrolyte battery Vented batteries usually have battery caps The caps may appear to be sealed but are not The caps should be removed periodically to check the level of electrolyte When a cell is low distilled water should be added after the battery is fully charged If the level is extremely low add only enough distilled water to cover the plates before recharging The electrolyte volume increa...

Page 48: ...making the adjustment Float voltage settings for NiCad NiFe batteries should also be set to the battery manufacturer s recommendations NOTE In all applications the BULK voltage setting should be adjusted to a level below the maximum operating voltage of the DC loads This may be as low as 15 volts for some types of electronic loads Undercharging may occur in this instance but DC equipment will be p...

Page 49: ...ming out of the source solar wind or hydro generator to a load which will utilize the excess power Usually a water heater or some other type of heating element is used for this purpose Systems utilizing solar arrays do not have a requirement for diversion loads since a solar module can be open circuited without damage However even with a solar based system it may be desirable to use excess power t...

Page 50: ...e element The remedy to this type of problem is to parallel several of these heater elements to increase the power output Table 10 below shows power dissipation of a 120 VAC 2000 watt heater element operated at different voltages Note that the voltages given are roughly the bulk charge stage voltages for a given system Remember that if you parallel heater elements the diversion load can handle mor...

Page 51: ...0 amps on the load controller s circuit Sizing a diversion system this way allows a safety margin for unusual conditions high winds high water flow etc It is not recom mended that light bulbs be used as diversion loads for a couple of reasons 1 An incandescent light bulb has a substantially lower cold filament resistance than when it is on This means it draws more power up to five times to start t...

Page 52: ... i d n I s u t a t S t c e n n o c s i D e g a t l o V w o L e d o M l o r t n o C d a o L e g r a h C n o i t a z i l a u q E e d o M l o r t n o C e g r a h C n o i t c e t o r P t i u c r i C t r o h S s t n i o p t e S l o r t n o C e l b a t s u j d A d l e i F h g i h r o f d e d i v o r p s t n i o p t s e t y c a r u c c a s u t a t s e g a t l o v y r e t t a b g n i t a r e p o e h t s e...

Page 53: ...mation or fax this page with the following information to 360 474 0616 Please provide Model Number Serial Number Purchase Date Problem Include a telephone number where you can be reached during business hours and a complete return shipping address P O Box numbers are not acceptable Name Address City State Province Zip Postal Code Country Phone FAX E mail Address visit our website at www traceengin...

Page 54: ...ed Service Center in the original packaging or equivalent The cost of transportation and insurance on items returned for service is the responsibility of the customer Return transporta tion UPS Ground or equivalent as well as insurance on all repaired items is paid by Xantrex Technology Inc All remedies and the measure of damages are limited to the above Xantrex Technology Inc shall in no event be...

Page 55: ...All manuals and user guides at all guides com ...

Page 56: ...visit our website at www traceengineering com 5916 195thStreetN E Arlington WA 98223 Phone 360 435 8826 Fax 360 435 2229 All manuals and user guides at all guides com a l l g u i d e s c o m ...

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