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Wiring

975-0004-01-02 Rev D

Table 2-4

One-Way Wire Distance and Wire Size

Maximum One-way Wire Distance for a < 3% Voltage drop

12 Vdc Application Shown

For 24 Vdc Systems, Multiply distance by 2
For 48 Vdc Systems, Multiply distance by 4

Distance in Feet (meters)

Distance in Feet (Meters)

a.These wire sizes are not approved by UL to be installed in the controller, but may be used
externally of the controller (using a splicer block) to reduce voltage drop and improve
performance.

Amps

AWG

1/0

AWG

2/0

AWG

8.8 ft.
(2.68 m)

14 ft.
(4.27 m)

22.2 ft.
(6.77 m)

35.3 ft.
(10.76 m)

56.1 ft.
(17.10 m)

70.9 ft.
(21.61 m)

89.6 ft.
(27.31 m)

112.5 ft.
(34.29 m)

141.7 ft.
(43.19 m)

225.8 ft.
(68.82 m)

7.3 ft.
(2.23 m)

11.6 ft.
(3.54 m)

18.5 ft.
(5.64 m)

29.4 ft.
(8.96 m)

46.7 ft.
(14.23 m)

59.1 ft.
(18.01 m)

74.6 ft.
(22.74 m)

93.7 ft.
(28.56 m)

118.1 ft.
(36.00 m)

188.2 ft.
(57.36 m)

6.3 ft.
(1.92 m)

10 ft.
(3.05 m)

15.9 ft.
(4.85 m)

25.2 ft.
(7.68 m)

40.1 ft.
(12.22 m)

50.6 ft.
(15.42 m)

64.0 ft.
(19.51 m)

80.4 ft.
(24.51 m)

101.2 ft.
(30.85 m)

161.3 ft.
(49.16 m)

5.5 ft.
(1.68 m)

8.7 ft.
(2.65 m)

13.9 ft.
(4.24 m)

22.1 ft.
(6.74 m)

35.0 ft.
(10.67 m)

44.3 ft.
(13.50 m)

56.0 ft.
(17.07 m)

70.3 ft.
(21.43 m)

88.6 ft.
(27.01 m)

141.2 ft.
(43.04 m)

4.9 ft.
(1.49 m)

8.8 ft.
(2.38 m)

12.4 ft.
(3.78 m)

19.6 ft.
(5.97 m)

31.2 ft.
(9.51 m)

39.4 ft.
(12.01 m)

49.8 ft.
(15.18 m)

62.5 ft.
(19.05 m)

78.7 ft.
(23.99 m)

125.5 ft.
(38.25 m)

4.4 ft.
(1.34 m)

7 ft.
(2.13 m)

11.1 ft.
(3.38 m)

17.6 ft.
(5.36 m)

28.0 ft.
(8.53 m)

35.4 ft.
(10.79 m)

44.8 ft.
(13.66 m)

56.2 ft.
(17.13 m)

70.9 ft.
(21.61m)

112.9 ft.
(34.41 m)

5.6 ft.
(1.71 m)

8.9 ft.
(2.71 m)

14.1 ft.
(4.30 m)

22.4 ft.
(6.83 m)

28.3 ft.
(8.63 m)

35.8 ft.
(10.91 m)

45.0 ft.
(13.72 m)

56.7 ft.
(17.28 m)

90.3 ft.
(27.52 m)

4.7 ft.
(1.43 m)

7.4 ft.
(2.26 m)

11.8 ft.
(3.60 m)

18.7 ft.
(5.70 m)

23.6 ft.
(7.19 m)

29.9 ft.
(9.11 m)

37.5 ft.
(11.43 m)

47.2 ft.
(14.39 m)

75.3 ft.
(22.95 m)

6.4 ft.
(1.95 m)

10.1 ft.
(3.08 m)

16.0 ft.
(4.88 m)

20.2 ft.
(6.16 m)

25.6 ft.
(7.80 m)

32.1 ft.
9.78 m)

40.5 ft.
(12.34 m)

64.5 ft.
(19.66 m)

5.6 ft.
(1.71 m)

8.8 ft.
(2.68 m)

14.0 ft.
(4.27 m)

17.7 ft.
(5.39 m)

22.4 ft.
(6.83 m)

28.1 ft.
(8.56 m)

35.4 ft.
(10.79 m)

56.5 ft.
(17.22 m)

7.8 ft.
(2.38 m)

12.5 ft.
(3.81 m)

15.7 ft.
(4.79 m)

19.9 ft.
(6.07 m)

25.0 ft.
(7.62 m)

31.5 ft.
(9.60 m)

50.2 ft.
(15.30 m)

7.1 ft.
(2.16 m)

11.2 ft.
(3.41 m)

14.2 ft.
(4.33 m)

17.9 ft.
(5.46 m)

22.5 ft.
(6.86 m)

28.3 ft.
(8.63 m)

45.2 ft.
(13.78 m)

6.3 ft.
(1.92 m)

9.3 ft.
(2.83 m)

11.8 ft.
(3.60 m)

14.9 ft.
(4.54 m)

18.7 ft.
(5.7 m)

23.6 ft.
(7.19 m)

37.6 ft.
(11.5 m)

Summary of Contents for Trace C35

Page 1: ...www xantrex com Smart choice for power C Series Multifunction DC Controller Manua C35 C40 C60 Owner s Manual ...

Page 2: ......

Page 3: ...C Series Multifunction DC Controller Owner s Guide ...

Page 4: ...d are used herein for identification purposes only Notice of Copyright C Series Multifunction DC Controller Owner s Guide November 2003 Xantrex International All rights 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 DO...

Page 5: ...formation about operating 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 Series Multifunction DC Controller Installers should be certified technicians or electricians Organization This Guide is org...

Page 6: ...dix A Specifications provide the specifications for the C Series Multifunction 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...

Page 7: ...antrex Technology Inc as well as its products and services at www xantrex com ASC Authorized Service Center BTS Battery Temperature Sensor CM C Series Meter CM R C Series Meter Remote DC Direct Current LCD Liquid Crystal Display LED Light Emitting Diode LVD Low Voltage Disconnect LVR Low Voltage Reconnect RE Renewable Energy ...

Page 8: ...vi ...

Page 9: ... enclosure to eliminate exposure to rain or water spray To reduce the chance of short circuits use insulated tools 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 exposure to live circuits The controller contains more than one live circuit batteries and PV array wind...

Page 10: ...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 the batteries Use insulated...

Page 11: ... Rev D ix CAUTION A battery can produce the following hazards to personal safety electrical shock burn from high short circuit current and or fire or explosion from vented gasses Observe proper precautions when working with or around batteries ...

Page 12: ...x ...

Page 13: ... 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 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 Mod...

Page 14: ... Process 33 Temperature Compensation 33 Temperature Compensation Based 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 Protection Requirements 39 Current Rating 39 Minimum Recommended Wire Gauge 40 Surge Protection 40 Over ...

Page 15: ...emperature 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 Troubleshooting 66 Load Control Troubleshooting 68 A Specifications Electrical Specifications 70 Features and Options Specifications 71 Environmental Specifications 72 B Batteries Battery Types 74 Aut...

Page 16: ...qualization 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 System 89 Index 91 ...

Page 17: ...per 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 Potentiometers pots 22 Figure 2 10 Bulk and Float Charge Settings for Charge Diversion 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 ...

Page 18: ...e 2 24 Diversion Control Mode Wiring 47 Figure 2 25 Load Control Mode Wiring 49 Figure 2 26 Installing a Digital Display 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 Panel Label 55 Figure 3 3 Reset Switch 61 ...

Page 19: ... 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 Ta...

Page 20: ...xviii ...

Page 21: ...tion 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 ...

Page 22: ...e 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 circuit breakers Adjustment of charge setpoints is provided by rotary controls potentiometers with removable knobs Calibra...

Page 23: ...o power generation system and protects the batteries from over discharge and over charge conditions The C Series has two operating modes Charge Control mode and Load Control mode determined by the Operating mode jumper See Figure 2 5 These two different operating modes allow the C Series to be installed and function as three different DC controllers Charge Control Mode PV Charge Controller control...

Page 24: ...ic 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 reduce...

Page 25: ...attery capacity is reached Float Stage 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 array When battery voltage drops below the float setting for a cumulative period of one hour a new bulk cycle will be triggered Figure 1 2 3 stage Battery Charging Process Bulk ...

Page 26: ...n how to set the voltage Manual or Auto Equalization Charge The C Series controller can be used to manually or automatically provide 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 Co...

Page 27: ...amps of continuous photovoltaic PV array current at 12 or 24 volts C60 or C35 models or 12 24 or 48 volts DC C40 model for charging batteries This rating includes the NEC required derating 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...

Page 28: ...vided with the PV modules Diversion Controller The C Series controller can operate as a Diversion Controller also called a shunt regulator to manage battery charging from alternative energy sources such as PV wind or hydroelectric generators A diversion controller monitors battery voltage and when the voltage exceeds the settings for your charge stage whether bulk or float the power is diverted fr...

Page 29: ...tive type heating elements are the best diversion loads Special direct current water heating elements are available Light bulbs and motors are not recommended as diversion loads because they are unreliable A diversion load that draws 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...

Page 30: ...ircuit board After the decal is in place replace the knobs The EQ jumper determines manual Important If PV arrays are used with diversion control it may be necessary to install diodes to prevent night time back feed If in doubt contact or consult with your local renewable energy expert Important If using multiple RE sources use diodes isolation to prevent backfeed CAUTION Damage to Batteries Curre...

Page 31: ... before the controller actually disconnects the load Low Voltage Reconnect It can also provide automatic reconnection of the loads at the LVR Low Voltage Reconnect setting Reconnection of the load is allowed once the battery voltage has exceeded the Low Voltage Reconnect LVR setting Loads are either automatically or manually reconnected when battery voltage exceeds the Low Voltage Reconnect LVR se...

Page 32: ...tions These meters provide a digital display of current voltage amperage and amp hours Battery Temperature Sensor BTS The BTS is installed on the side of the battery and attaches to the circuit board inside the C Series controller It provides accurate sensing of the battery temperature and uses this reading to control charging Using this accessory can extend battery life and improve overall chargi...

Page 33: ...troller For information on See Pre Installation page 14 Mounting the Controller page 16 Configuring the C Series Controller page 18 Adjusting the C Series Voltage Settings page 22 Grounding page 37 Wiring page 38 Installing Optional Accessories page 50 Installing the Battery Temperature Sensor page 51 ...

Page 34: ...he unit Removing Knockouts Six dual knockouts are provided to accommodate the necessary wiring of the C Series controller Be sure to remove any metal shavings created by removing the Important Installations should meet all local codes and standards Installations of this equipment should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy RE System I...

Page 35: ...ockout holes Figure 2 2 C Series Dimensions and Knockout Locations Not to Scale Side View Rear View 8 203 mm 6 7 8 174 mm 8 203 mm 2 51 mm 2 64 mm 5 127 mm 3 5 8 93 mm Heatsink not included on C35 This distance varies per model C35 3 8 C40 C60 5 8 and Dual Knockouts and 1 Dual Knockouts x4 1 on each side and 2 on the bottom of chassis Keyhole Slots for mounting 1 2 1 2 Additional Mounting Holes x4...

Page 36: ... mark the location of the keyhole slots on the wall 3 Move the controller out of the way and secure two mounting screws in the locations marked Leave the screw heads backed out approximately inch 6 mm or less 4 Place the controller onto the screws and pull it down into the keyhole slots 5 Then insert the two more screws in two of the four additional mounting holes provided to secure the enclosure ...

Page 37: ... a sealed compartment 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 Figure 2 3 Mounting the C Series Multifunction DC Controller Mounting Surface Secure in place with 2 more screws Place keyhole slots on the back of the controller over the mounting screws...

Page 38: ...tery voltage and operating modes They must be installed correctly for the unit to operate to its maximum potential To enable a selection carefully slide the jumper over the top of both pins This is called installing the jumper To disable a selection carefully slide the jumper over only one of the pins This is called removing the jumper The factory default settings are shown in Table 2 1 Factory De...

Page 39: ...ualization Operating Mode Charge Control Figure 2 5 Circuit Board Components Operating Mode Jumper Reset Switch Voltage Jumper EQ LVR Jumper DC Terminal Connectors Potentiometers Battery Temperature Sensor Port NiCad Setting Selection R46 Resistor CM or CM R Port Note This photograph shows the Load Control Voltage decal installed on the circuit board over the potentiometers Load Control Decal ...

Page 40: ...er The voltage jumper determines the voltage of the system that the controller will be used with To set the voltage place the jumper over the two pins adjacent to the legend for the voltage of your system 12 24 48 Factory setting is 12 volts for the C35 C40 and C60 Figure 2 6 Mode of Operation Jumper Figure 2 7 Voltage Selection Jumper Charge Load Control Jumper Charge Control Mode Load Control Mo...

Page 41: ... days This can be done manually by using Reset Switch on the side of the controller chassis When AUTO is enabled in Load Control mode the unit will reconnect automatically when voltage at the BATTERY POSITIVE terminal exceeds the LVR setting This can also be done manually by using Reset Switch on the side of the controller chassis The factory default setting is MANUAL EQUALIZATION Charge Control m...

Page 42: ...eter For more information regarding bulk and float charging voltages see Three Stage Battery Charging on page 4 Setting Voltage Parameters for Charge Control Mode To set the controller to a specific voltage point the setting indicator at the scale mark representing the desired voltage The potentiometer scale for BULK charge voltage is calibrated as follows 12 volt system 13 0 to 15 0 volts in incr...

Page 43: ...0 Bulk and Float Charge Settings for Charge Diversion Control Mode 15 0 13 0 14 0 BULK CHG 13 2 13 4 13 6 13 8 14 2 14 4 14 6 14 8 FLOAT CHG 14 5 12 5 13 5 12 7 12 9 13 1 13 3 13 7 13 9 14 1 14 3 30 0 26 0 28 0 BULK CHG 26 4 26 8 27 2 27 6 28 4 28 8 29 2 29 6 FLOAT CHG 29 0 25 0 27 0 25 4 25 8 26 2 26 6 27 4 27 8 28 2 28 6 60 0 52 0 56 0 BULK CHG 52 8 53 6 54 4 55 2 56 8 57 6 58 4 59 2 FLOAT CHG 5...

Page 44: ...potentiometer becomes the Low Voltage Disconnect LVD Place the sticker provided over the potentiometers The knobs may have to be removed for sticker placement then reinstalled The sticker is packed inside the C Series controller bottom of unit If the decal is lost or unavailable you can recalculate the appropriate voltage settings as follows The scale for the Low Voltage Reconnect setting is calib...

Page 45: ...Settings 24 Volt System Settings 14 0 12 0 13 0 L V R LOAD LOW VOLTAGE RECONNECT 12 2 12 4 12 6 12 8 13 2 13 4 13 6 13 8 12 5 10 5 11 5 10 7 10 9 11 1 11 3 11 7 11 9 12 1 12 3 L V D LOAD LOW VOLTAGE DISCONNECT 28 0 24 0 26 0 24 4 24 8 25 2 25 6 26 4 26 8 27 2 27 6 25 0 21 0 23 0 21 4 21 8 22 2 22 6 23 4 23 8 24 2 24 6 L V R LOAD LOW VOLTAGE RECONNECT L V D LOAD LOW VOLTAGE DISCONNECT 56 0 48 0 52 ...

Page 46: ... voltage to the FLOAT voltage setting This will usually result in more current being diverted to the diversion load Setting Voltage Parameters for Alkaline Batteries If using NiCad or NiFe batteries the required charging voltages may be higher than the designed settings of the C Series controller Charging voltages can be augmented a little if required This can be accomplished by clipping the wire ...

Page 47: ... LVR jumper is on the MANUAL Setting 12 Volt System Settings 24 Volt System Settings 17 0 15 0 16 0 BULK CHG 15 2 15 4 15 6 15 8 16 2 16 4 16 6 16 8 FLOAT CHG 16 5 14 5 15 5 14 7 14 9 15 1 15 3 15 7 15 9 16 1 16 3 48 Volt System Settings C40 only 34 0 30 0 32 0 BULK CHG 30 4 30 8 31 2 31 6 32 4 32 8 33 2 33 6 FLOAT CHG 33 0 29 0 31 0 29 4 29 8 30 2 30 6 31 4 31 8 32 2 32 6 68 0 60 0 64 0 BULK CHG ...

Page 48: ...e terminals on the circuit board and the small test point located to the left of each potentiometer at the nine o clock position See Figure 2 15 The test point provides a reading from 0 to 2 volts Multiply this value by 2 for 24 volt system and by 4 for 48 volt system 3 Add the value obtained in step 2 above to the lower value of the adjustment range voltage scale being used For example for a 12 v...

Page 49: ... voltage to 56 4 volts 1 Point the BULK potentiometer to the mid range position 2 Adjust the potentiometer until the DVM displays 1 1 volts 1 1 x 4 48 volt 4 4 52 0 56 4 Figure 2 15 Test Points for Adjusting Voltage Using a DVM Battery Common Negative Terminals TEST POINTS for DVM center legs of potentiometer ...

Page 50: ...ting for this feature is MANUAL Automatic equalization is enabled by moving the jumper located on the right side of the circuit board above the reset switch to the appropriate AUTO pin set See Figure 2 18 When automatic has been selected an equalization charge will occur every 30 days During the equalization process the status LED indicates equalization by alternately blinking green and red CAUTIO...

Page 51: ...y voltage has been at or above the bulk setting for a cumulative period of two hours the C Series will return to the float stage of the charging process During the equalization process the status LED will alternate between red and green and will not provide any other mode status indication Large battery banks may need several equalization cycles to fully stir the electrolyte and charge the cells T...

Page 52: ...tart counting the voltage may not reach the equalization voltage setting To enable automatic equalization the jumper located on the right side of the circuit board must be moved to the AUTO setting The default setting of the C Series controller is for manual equalization To disable the automatic equalization system move the equalize jumper to MANUAL Once a manual equalization has been triggered th...

Page 53: ...returning to the float setting Temperature Compensation For optimal battery charging the Bulk and Float charge rates should be adjusted according to the temperature of the battery When battery charging voltages are compensated based on temperature the charge voltage will vary depending on the temperature around the batteries Figure 2 19 Terminating the Equalization Charge Important If using the C ...

Page 54: ...ensation calculations for a Lead Acid type battery as show in Table 2 2 Lead Acid Type Batteries 5 mV per cell per degree Celsius Alkaline Type Batteries NiCad or NiFe 2 mV per cell per degree Celsius Table 2 2 describes approximately how much the voltage may vary depending on the temperature of the batteries Automatic Battery Temperature Compensation Temperature compensation can be accomplished a...

Page 55: ...0 40 1 20 0 80 2 40 1 60 40 104 0 45 0 30 0 90 0 60 1 80 1 20 35 95 0 30 0 20 0 60 0 40 1 20 0 80 30 86 0 15 0 10 0 30 0 20 0 60 0 40 25 77 0 00 0 00 0 00 0 00 0 00 0 00 20 68 0 15 0 10 0 30 0 20 0 60 0 40 15 59 0 30 0 20 0 60 0 40 1 20 0 80 10 50 0 45 0 30 0 90 0 60 1 80 1 20 5 41 0 60 0 40 1 20 0 80 2 40 1 60 0 32 0 75 0 50 1 50 1 00 3 00 2 00 5 23 0 90 0 60 1 80 1 20 3 60 2 40 10 14 1 05 1 20 2...

Page 56: ... very hot or very cold conditions adjust the bulk and float settings to allow for the battery temperature The recommended adjustments can be made following Table 2 2 The setting should be lowered for ambient temperatures above 86 F 30 C and raised for ambient temperature below 68 F 20 C If significant seasonal variations are common you will have to change the settings several times a year to preve...

Page 57: ...tor to the grounding system at one point in the system Consult local and national electrical codes for more information and any additional requirements Telecom applications often require a positive ground system The C Series controller switches the PV LOAD terminal with the BATTERY POSITIVE terminal These terminals must be kept separate You can ONLY ground the battery positive lead in this case if...

Page 58: ...on to one another Important Installations should meet all local codes and standards Installations of this equipment should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy RE System Installers For a list of Xantrex Certified RE dealers please visit our website at www XantrexREdealers com WARNING Shock Hazard Disconnect battery and PV sources befo...

Page 59: ...nal and local electrical code requirements Wiring should be protected from physical damage with conduit or a strain relief clamp You should pull the temperature sensor cable through the conduit first as the connector may not fit if other wires have been pulled first Current Rating Each model of the C Series controller is rated for a maximum continuous current of 35 40 or 60 amps Since PV outputs c...

Page 60: ...equired Surge Protection Since PV arrays are often mounted on an elevated structure and thus are more susceptible to lightning strikes protection from lightning induced power surges and other transient power disturbances between the PV array and the C Series Figure 2 22 AWG Wire Gauge Reference Chart Important Figure 2 22 is for reference only Sizes shown are for the conductor Do not include any i...

Page 61: ... rated current limiting fuse or circuit breaker should be installed near the battery for protection from short circuits To meet NEC requirements use a 60 amp circuit breaker listed for 100 duty for the C60 To meet UL requirements use 6 AWG copper wires rated for 90 C 194 F for the C60 Over current protection for the battery circuit is to be provided by others Refer to Table 2 3 for the correct rat...

Page 62: ...ng if required Splicer blocks and split bolt kerneys are available from renewable energy suppliers Maximum One way Distance and Wire Size Refer to Table 2 4 and find your maximum current in the left column and the one way distance from your power source feet meters to the C Series controller or the distance from the C Series controller to your load on the same line then read the wire size required...

Page 63: ...m 22 1 ft 6 74 m 35 0 ft 10 67 m 44 3 ft 13 50 m 56 0 ft 17 07 m 70 3 ft 21 43 m 88 6 ft 27 01 m 141 2 ft 43 04 m 18 4 9 ft 1 49 m 8 8 ft 2 38 m 12 4 ft 3 78 m 19 6 ft 5 97 m 31 2 ft 9 51 m 39 4 ft 12 01 m 49 8 ft 15 18 m 62 5 ft 19 05 m 78 7 ft 23 99 m 125 5 ft 38 25 m 20 4 4 ft 1 34 m 7 ft 2 13 m 11 1 ft 3 38 m 17 6 ft 5 36 m 28 0 ft 8 53 m 35 4 ft 10 79 m 44 8 ft 13 66 m 56 2 ft 17 13 m 70 9 ft...

Page 64: ...he DC disconnect 6 Route a negative wire from the PV GFP to the Negative bus in the DC disconnect 7 Connect a positive cable from terminal marked BAT POS to the battery disconnect in the DC disconnect 8 Connect a second positive cable to the other side of the battery disconnect in the DC disconnect and connect to the positive battery terminal 9 Connect the negative battery cable to the negative bu...

Page 65: ... Rev D 45 Figure 2 23 PV Charge Control Mode Wiring 4 2 1 7 5 6 8 A 3 9 A Battery Positive PV Array Positive PV Array Negative Battery Negative Common Negatives Ensure the proper grounding is in place for the entire system ...

Page 66: ...onnect a cable from controller terminal marked BAT POS to the battery disconnect 5 Connect a cable from the battery disconnect to the positive terminal of the battery 6 Connect a cable from the negative battery terminal to one of the terminals marked COMMON NEGATIVES on the controller s circuit board 7 Connect a cable from the controller s other terminal marked COMMON NEGATIVES to the negative ter...

Page 67: ...D 47 Figure 2 24 Diversion Control Mode Wiring 4 2 1 7 5 6 8 A 3 Ensure the proper grounding is in place for the entire system A Battery Positive Diversion Load Positive Diversion Load Negative Battery Negative Common Negatives ...

Page 68: ...able to the battery disconnect 3 Connect the negative battery cable to the one of the terminals marked COMMON NEGATIVES 4 Connect a cable between the PV POS LOAD terminal on the controller and the positive terminal on the DC load 5 Connect a cable between the controller s other COMMON NEGATIVES terminal and to the negative terminal of the load 6 Tighten per torque requirements outlined on page 39 ...

Page 69: ...Wiring 975 0004 01 02 Rev D 49 Figure 2 25 Load Control Mode Wiring 4 2 1 5 3 Battery Positive DC Load Positive DC Load Negative Battery Negative Common Negatives ...

Page 70: ...ide for preparing the CM or CM R for installation The display will connect to the controller at the RJ 15 port on the lower left corner of the circuit board Important Ensure the voltage jumpers on the back of the CM or CM R match the system voltage as configured inside the controller unit See the C Series Meter Displays Installation Guide for additional information Figure 2 26 Installing a Digital...

Page 71: ... the batteries in an insulated box to reduce the influence of the ambient temperature outside the battery enclosure 2 Insert the RJ 11 plug on the other end of the BTS into the BTS Port on the lower right corner of the circuit board inside the C Series controller Important Ventilate the battery box at the highest point to prevent hydrogen accumulation Figure 2 27 Installing the BTS C Series Circui...

Page 72: ... on the C Series controller 1 Align faceplate with front of chassis so that screw holes in the corners line up 2 Insert the phillips screws into the screw holes and tighten Figure 2 28 Re installing the CM Faceplate Align these screw holes Replace the phillips screws to secure the faceplate ...

Page 73: ...ies Multifunction DC Controller For Information on See Basic Operation page 54 LED Status Indicator page 55 Charge Control or Diversion Control Indications Green page 56 Load Control Indications Red page 58 Error Mode Indication Orange page 59 Reconnecting to Loads page 60 ...

Page 74: ...Basic Operation The C Series controller all models has one multicolor LED status indicator and one reset button Figure 3 1 C Series Status LED and Reset Button Location Multicolor LED indicator Reset Switch Reset Switch on side of unit ...

Page 75: ...nates between red and green Important The green and red color of the LED only indicates the particular operating mode and the battery voltage level It does not indicate whether the charging source is functioning properly Figure 3 2 C Series Front Panel Label Green Blink Charge Control Mode Green Solid Battery Charged Green Red Blink Load Control Mode Red Solid Battery Discharged Red C35 C40 C60 12...

Page 76: ...means the controller is in the Float stage and is regulated at the Float voltage Table 3 1 Battery Voltage LED Indicators Green LED Charge Diversion Mode LED Status Red LED Load Control Mode Battery at FLOAT Setting Always ON Battery at LVD Setting for 6 minutes LVD Battery at BULK Setting 5 blinks 0 15 above LVD 0 03 above LVD 0 45 above LVD BULK Setting Minus LVD Setting Plus 0 25 Vdc 0 50 Vdc 1...

Page 77: ...l blink green several times up to five and then pause indicating the battery voltage is approaching the bulk setting and provides an indication of the battery condition Refer to Table 3 1 to determine the battery voltage Solid Green The battery is being charged in the FLOAT stage The status LED remains ON solid unless the batteries drop below the float voltage setting for an accumulative period of...

Page 78: ...sing the reset switch until the status LED stops alternating red and green Load Control Indications Red The flashing rate of the LED indicates the controller s stage of operation and approximate battery voltage Blinking Red As battery voltage approaches the LVD setting the LED will blink red several times up to five and then pause providing an indication of battery voltage Refer to Table 3 1 to de...

Page 79: ...n to reduce the charge rate This will reduce the transistor temperature In Load Control mode the load is disconnected before the transistors reach an excessive temperature Once the temperature has dropped the loads are reconnected Over Current Condition During operation the C Series controller continuously monitors the current flowing through it If the current exceeds 85 amps the transistor switch...

Page 80: ...ng to allow an automatic reset to occur if the EQ LVR Auto jumper is set to AUTO Slow Blinking Orange When the disconnect reconnect system has been activated the LED will slowly blink orange The controller is in the DC Load Control mode and has disconnected the loads due to reaching the LVD setting Reconnecting to Loads To reconnect the loads press the reset button on the right side of the unit If...

Page 81: ...ion in Charge Control mode press and hold the Reset Switch until the red and green LED stop flashing To reset following an error condition press and release the Reset Switch To reset following a low voltage disconnect press and release the Reset Switch See Reconnecting to Loads for additional information about reconnecting to loads Important The LED will light red only in Load Control mode never i...

Page 82: ...62 ...

Page 83: ...mation about identifying and resolving possible problems with systems using a C Series Multifunction DC Controller For Information on See PV Charge Control Troubleshooting page 64 Diversion Control Troubleshooting page 66 Load Control Troubleshooting page 68 ...

Page 84: ...Battery terminal are from the correct sources Controller is locking up PV positive and Battery positive wires have been swapped Verify the voltage on PV terminal and Battery terminal are from the correct sources Status LED Blinks Orange after switching on array breaker PV wires are connected in reverse polarity Verify PV polarity relative to battery negative Status LED Blinks Orange at times durin...

Page 85: ...A Check array output B Set controllers to the same settings C Check wiring D Try a different controller if metering is unacceptable Status LED blinks red while mode jumper is in charge control but still regulates normally LED may have been reinstalled backwards Remove LED and install correctly Flat side of LED should be on left side Battery voltage is exceeding Bulk and Float settings in cold weat...

Page 86: ...oltage is applied across it Note A diversion load with an acceptable hot current may have an excessively high inrush current that can cause the controller to overcurrent Caution Do not test without a circuit breaker in circuit Battery voltage is exceeding Bulk or Float settings A BTS is compensating charging voltages based on battery temperature B Diversion load is too small for output of charging...

Page 87: ...er settings A Bulk voltage on controller needs to be set higher than other charging sources or use a switch relay to disable the diversion load while using a generator Diversion load operates immediately at full power when load breaker is turned on Mode jumper is set for Load Control instead of Charge Control Change jumper setting Table 4 2 Diversion Control Problems Problem Possible Cause Solutio...

Page 88: ...ol decal is not in place B BTS has been installed A Install the decal or follow procedure in manual See Setting Voltage Parameters for Load Control Mode on page 24 B Battery Temperature Sensors should not be used in load control applications Status LED Blinks Orange after switching on the load breaker Startup or Inrush current exceeds controller rating Use larger controller or buffer the controlle...

Page 89: ...A Specifications provide the specifications for the C Series Multifunction DC Controller For information on See Electrical Specifications page 70 Features and Options Specifications page 71 Environmental Specifications page 72 ...

Page 90: ...rated Maximum Short Circuit Current 85 amps intermittently 85 amps intermittently 85 amps intermittently Maximum Voltage Drop 0 30 volts charge control mode Total Current Consumption While operating 15 mA typical at idle 3 mA tare Charger Regulation Method Solid state 3 stage bulk absorption and float Pulse Width Modulation PWM Charging Control Settings Lead Acid Battery 12 Volt System Float 12 5 ...

Page 91: ...User selectable manual or automatic reconnection includes warning flash before disconnect and 6 minutes grace period Equalization Charge Charge Control Mode User selectable manual or automatic equalization every 30 days Short Circuit Protection Fully electronically protected with auto reset Adjustable Control Setpoints test points provided for high accuracy Two user adjustable voltage setpoints fo...

Page 92: ...104 F 0 to 40 C Specifications at 25 C Non operating Temperature 67 to 284 F 55 to 75 C Specifications at 25 C Altitude Limit operating 15 000 feet 5 000 meters Altitude Limit non operating 50 000 feet 16 000meters Dimensions H x W x D 8 x 5 x 2 5 20 3 cm x 12 7 cm x 6 35 cm 10 x 5 x 2 5 25 4 cm x 1 7 cm x 6 35 cm Mounting Vertical Wall Mount Weight Controller only 2 5 lbs 1 2 kg 3 0 lbs 1 4 kg 3 ...

Page 93: ...BBatteries Appendix B Batteries describes types of batteries For information on See Battery Types page 74 Battery Sizing page 76 Equalization Charging page 77 ...

Page 94: ...on Maintenance Free Batteries This type of battery is often sold as a RV or marine battery but is rarely appropriate for use with a PV system They typically have an additional reserve of electrolyte but are vented This is not the same as a sealed battery Deep Cycle Batteries Best suited for use with PV systems this type of battery is designed to be more deeply discharged before being recharged Dee...

Page 95: ...4 or Group 27 batteries and are rated at 80 to 100 amp hours at 12 volts Many larger systems use L16 batteries which are usually rated at 350 amp hours at 6 volts each They are 17 inches high and weigh about 130 pounds 8D batteries are available with either cranking or deep cycle construction Purchase only the deep cycle version The 8D is typically rated at 220 amp hours at 12 volts Sealed Batteri...

Page 96: ...rt battery life and disappointing system performance To determine the proper battery bank size compute the number of amp hours that will be used between charging cycles Once the required amp hours are known size the batteries at approximately twice this amount Doubling the expected amp hour usage ensures that the batteries will not be overly discharged and will extend battery life Important In all...

Page 97: ...e lower portion of the plates reducing battery life Mixing of the electrolyte by the formation of gas bubbles during the equalization process reduces stratification Two methods can be used to determine if a battery needs to be equalized If possible measure the voltage of each individual cell while the battery is at rest not being charged or discharged A variation of 0 05 volts between cells indica...

Page 98: ...er to the battery following the equalization process CAUTION Damage to Loads DC loads may need to be disconnected by turning off circuit breakers or removing fuses before equalization to prevent damage by the required higher voltages used in the equalization process CAUTION If the batteries are equipped with hydro caps catalytic gas recombiner caps they should be removed during the equalization pr...

Page 99: ... Charge to 15 5 Vdc or per battery manufacturer NiCad or NiFe Alkaline Batterya a For NiCad and NiFe batteries you must clip the R46 resistor and add 2 volts to the values for BULK AND FLOAT shown on the circuit board For example set the BULK for 16 0 V adjust the BULK knob to 14 0 V after clipping R46 Values above are for batteries at room temperature For applications with significant temperature...

Page 100: ...80 ...

Page 101: ...CDiversion Loads Appendix C Diversion Loads provides additional information about Diversion Loads For information on See Diversion Load Types page 82 ...

Page 102: ...rent capability of the charging source s These heater elements were designed to operate at 120 volts AC A 48 volt 40 amp charge controller will operate just fine with this type of a system providing about 500 watts of power dissipation A 12 or 24 volt diversion load controller will work but doesn t put out enough power to effectively heat water with only one element The remedy to this type of prob...

Page 103: ...ich are capable of putting out more than 32 amps 80 of 40 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 recommended 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 Thi...

Page 104: ...84 ...

Page 105: ...ding replacement products Xantrex reserves the right to use parts or products of original or improved design in the repair or replacement If Xantrex repairs or replaces a product its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipment to the customer whichever is greater All replaced products and all parts removed from repair...

Page 106: ...n misused neglected improperly installed physically damaged or altered either internally or externally or damaged from improper use or use in an unsuitable environment b the product if it has been subjected to fire water generalized corrosion biological infestations or input voltage that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex product specifications ...

Page 107: ... rights You may have other rights which may vary from state to state or province to province Warning Limitations On Use Please refer to your product manual for limitations on uses of the product SPECIFICALLY PLEASE NOTE THAT THE C SERIES MULTIFUNCTION DC CONTROLLER SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES WITHOUT LIMITING THE GENERALITY OF TH...

Page 108: ...oduct to a Xantrex Authorized Service Center ASC A Xantrex return material authorization RMA number is not required However you must contact the ASC prior to returning the product or presenting the unit to verify any return procedures that may apply to that particular facility Out of Warranty Service If the warranty period for your C Series Multifunction DC Controller has expired if the unit was d...

Page 109: ...m _______________________________ Purchase Date _______________________________ Type of installation e g RV truck vehicle home ______________________________ Length of time inverter has been installed ______________________________ Battery battery bank size ______________________________ DC wiring size and length ______________________________ Warning Error or Panel Fault Message _________________...

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Page 111: ...ization Charging 30 Equalization Mode Indication 57 Error Mode Indication 59 F FLOAT charge voltage 23 G Grounding 37 I Information about Your System form 89 J Jumper Settings 18 K Knockouts 14 L LED Status Indicator 55 Load Control Indications 57 Low Voltage Disconnect 25 Low Voltage Reconnect 24 M Manual Equalization 31 N National Electrical Code 3 O Operating Mode Jumper 20 Over Current 59 Over...

Page 112: ... S Safety Instructions vii serial number 89 T Test Points for Voltage Settings 28 Torque Requirements 39 Troublshooting 64 V Voltage Jumper 20 W warranty out of warranty service 88 terms and conditions 85 Wire Size 39 Wiring 38 X Xantrex web site v ...

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Page 114: ...x Technology Inc 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice xantrex com www xantrex com 975 0004 01 02 Printed in China ...

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