Coleman Air C60-PWM 60 Amp Solid State PWM Charge Controller 12 or 24 volt battery based systems Version 2.
The Coleman Air C60-PWM Charge Controller This controller is suitable for operation in a 24-volt system, which may have charge and overcharge voltages exceeding 60 volts. 60+ volts at these amperages can be LETHAL! – It only takes a micro-amp and the right (or wrong conditions) at higher voltages to kill you! Don’t take chances! Use extreme caution when installing or servicing this controller. Always disconnect the energy source before servicing this unit.
Introduction This solid-state (no relays or solenoids) charge controller has been specifically designed for medium sized solar or turbine, battery based alternate energy systems of up to 60 amps. The Coleman Air C60-PWM uses two highpower (230 amps each), in a back-to-back configuration, allowing a significant increase in total current handling capability over competing models in this price range.
The front panel decal Float Mode Bulk Mode Equalize Mode Overheat Over-current Set Point Reached (Solar) 1 sec. flashes, normal mode 5 sec. flashes EDM mode Empowering Innovation Press and hold the equalize button during power up to enable the automatic 30 day equalization. The front panel decal describes the functionality of the two LED’s (Green and Red) Float Mode Active: Indicated by a single repeating flash of the green LED (on/off/on/off etc.
Some specifics The microprocessor is the heart of the controller. The battery level is constantly checked by the microprocessor and compared to the active mode’s (Float, Bulk or Equalize) set point to determine how much (if any) current should flow into or out of the batteries. As the battery’s level of charge increases, so does the voltage of the battery (the battery’s level of charge can be determined by the voltage of the battery.
The Three Stage Charging processes in detail: The main advantage to solid-state controllers is that they offer more advanced charging modes than single stage controllers.
Selecting your battery system voltage (Jumper settings) The Coleman Air C60-PWM can handle 12 or 24 volt battery based systems. To set the controller for use with a 12-volt system, place the jumper in the 1st position closest to the top; use the 2nd position for 24-volt systems. Blow up of jumper To change the voltage selection, Remove this jumper with your fingernails or carefully using a Small pair of pliers, and place it across the desired two pins of the voltage selection.
Using the C60-PWM as a Solar Charge Controller Series disconnect charge controllers are used with solar systems and other energy sources where the charge source does not require a constant load. In this mode, the charge source is simply disconnected from the batteries once the active trip point is reached. It is then reconnected as soon as the battery voltage drops a little.
Using the C60-PWM as a Diversion Charge Controller Diversion controllers are generally used with turbine-based systems and other energy sources where the charge source requires a constant load. In this mode, the charge source is not disconnected from the batteries; but instead once the active trip point is reached; the excess energy is routed to a diversion load (or useful load). Once the battery voltage drops a little, the load is disconnected.
About load diversion (For wind/hydro turbines) 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.
Water heating elements designed specifically for 12 and 24 volt systems are by far a better choice. A very acceptable diversion load is a power resistor. These can be obtained via the www.ColemanAir.us website. Various wattages are available as either completed load centers or individual power resistors. Product Code: L675W12V 45A/12V 675 Watt Diversion Dummy Load Resistor Heater -- For 12 volt systems Product Code: 2R100W 2 Ohm, 100 Watt power resistor for 12v systems.
Extended Diversion Mode -- EDM 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, of sufficient size, to the battery or energy source to prevent the battery voltage from increasing any further. The amount of time the diversion load is connected is generally only a few seconds (or less).
Calibrating the Controller 9 4 15 .0 14.8 14.67 .4 14 14 .22 14.0 Bulk 4 14 .5 14.3 9 14.17 .9 14 14 .72 13.5 Meter probe location .0 13 1 13.1 13.33 13 .56 78 13. Float .5 12 1 12.6 12.83 13 .06 28 13. PCB set point adjustments The controller has already been calibrated by the factory using the following settings, and does not require calibration unless the factory set points are not satisfactory for your installation. Factory Defaults: Float Set Point: 13.
If you would like to change either set point, please use one of the following procedures. Use a Small screwdriver; an oversized tool may damage the potentiometers! Method 1: If you own a variable voltage power supply and would like to calibrate the unit on the bench or while it is disconnected from the main system, then the following procedure is recommended.
The bulk setting voltage range is 13 to 15 volts, also a 2-volt span. To set the bulk setting to say 14.4 volts: (14.4 – 13) / 2 * 5 = 3.5 volts – You would set the bulk potentiometer to 3.5 volts (as read with the volt/ohm meter at the test probe location) – This will result in the bulk setting for the controller to be at exactly 14.4 volts.
General Operating Specifications 12V 24V Minimum operating voltage Maximum allowable intermittent/surge voltage (1) 8.5v 45v 8.
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