Smart choice for power C35 C40 C60 Owner’s Manual C-Series Multifunction DC Controller Manual Type www.xantrex.
C-Series Multifunction DC Controller Owner’s Guide
About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.
About This Guide Purpose The purpose of this Guide is to provide explanations and procedures for installing, operating, maintaining, and troubleshooting the C-Series Multifunction DC Controller. Scope This Guide provides safety guidelines, detailed planning and setup information, procedures for installing the inverter, as well as information about operating and troubleshooting the unit. It does not provide details about particular brands of batteries.
About This Guide Chapter 2 contains information and procedures to install C-Series Multifunction DC Controller. Chapter 3 contains information about the operation of a C-Series Multifunction DC Controller. Chapter 4, “Troubleshooting” contains information about identifying and resolving possible problems with systems using a C-Series Multifunction DC Controller. Appendix A, “Specifications” provide the specifications for the C-Series Multifunction DC Controller.
About This Guide Abbreviations and Acronyms 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 Related Information You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com.
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Important Safety Instructions WARNING This manual contains important safety instructions that should be followed during the installation and maintenance of this product. Be sure to read, understand, and save these safety instructions. General Safety Instructions • • • • • • • All electrical work must be done in accordance with local, national, and/or international electrical codes.
Safety Battery Safety Information • • • • • • • • • • • • • • • viii Always wear eye protection, such as safety glasses, when working with batteries. Remove all jewelry before working with batteries. Never work alone. Have someone assist you with the installation or be close enough to come to your aid when working with batteries. Always use proper lifting techniques when handling batteries. Always use identical types of batteries. Never install old or untested batteries.
Battery Safety Information 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.
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Contents Important Safety Instructions 1 - - - - - - - - - - - - - - - - - -vii Introduction Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 Operating Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 Charge Control Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 Three-Stage Battery Charging - - - - - - - - - - - - - - - - - - - 4 Battery Temperature Compensation - - - - - - - - - - - - - - - 6 Manual or Auto Equalization Charge
Contents Automatic/Manual Battery Equalization (EQ) and Low Voltage Reconnect (LVR) Jumper - - - - - - - - - - - - - Adjusting the C-Series Voltage Settings - - - - - - - - - - - - - - - - Setting Voltage Parameters for Charge Control Mode- - - - Setting Voltage Parameters for Load Control Mode - - - - - Setting Voltage Parameters Diversion Control Mode - - - - Setting Voltage Parameters for Alkaline Batteries - - - - - - Using a Digital Voltmeter to Adjust Voltage Settings - - - - Equalization Charging- -
Contents 3 Operation Basic Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LED Status Indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - Charge Control or Diversion Control Indications (Green) - Blinking Green - - - - - - - - - - - - - - - - - - - - - - - - - - - Solid Green - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Equalization Mode Indication (Red/green) - - - - - - - - Load Control Indications (Red) - - - - - - - - - - - - - - - - - - - Blinking
Contents Battery Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76 Equalization Charging- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77 Equalization Setpoints (Non-Sealed Batteries Only) - - - - - - 79 C Diversion Loads Diversion Load Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82 Warranty and Product Information Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Disclaimer - - - - - - - - - - - - - - - - - - - -
Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 2-13 Figure 2-14 Figure 2-15 Figure 2-16 Figure 2-17 Figure 2-18 Figure 2-19 Figure 2-20 Figure 2-21 C-Series Multifunction DC Charge Controllers - - - - - - 2 3-stage Battery Charging Process - - - - - - - - - - - - - - - 5 PV Charge Controller - - - - - - - - - - - - - - - - - - -
Figures Figure 2-22 Figure 2-23 Figure 2-24 Figure 2-25 Figure 2-26 Figure 2-27 Figure 2-28 Figure 3-1 Figure 3-2 Figure 3-3 xvi AWG Wire Gauge Reference Chart - - - - - - - - - - - - PV Charge Control Mode Wiring - - - - - - - - - - - - - Diversion Control Mode Wiring - - - - - - - - - - - - - - Load Control Mode Wiring - - - - - - - - - - - - - - - - - Installing a Digital Display - - - - - - - - - - - - - - - - - - Installing the BTS - - - - - - - - - - - - - - - - - - - - - - - - Re-installing the CM
Tables Table 2-1 Table 2-2 Table 2-3 Table 2-4 Table 3-1 Table 4-1 Table 4-2 Table 4-3 Table A-1 Table A-2 Table A-3 Table B-1 Table C-1 Factory Default Settings for C-Series Controllers- - - Variances in Charging Voltage based on Battery Temperature - - - - - - - - - - - - - - - - - - - - - - Minimum Wire Size - - - - - - - - - - - - - - - - - - - - - - One-Way Wire Distance and Wire Size - - - - - - - - - Battery Voltage LED Indicators - - - - - - - - - - - - - - PV Charge Control Problems - - - - - - -
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1 Introduction Chapter 1 describes features and functions of the C-Series Multifunction DC Controller.
Introduction Features The C35/C40/C60 (C-Series) controllers can be used with 12-volt, 24-volt, or 48-volt DC systems (depending upon model) as Charge Controller or a Load Controller.
Operating Modes • • • • • Indoor-type, powder-coated enclosure, for wall mounting. Conformal-coated circuit boards, plated terminals, powder-coated metal components, and stainless steel fasteners improves tolerance to hostile environments. Meets National Electrical Code (NEC) and other international controller specifications. The C35, C40 and C60 models are UL listed to the U.S. UL Standard 1741 (1st edition), and Canada (CSA-C22.2 No. 107.1-95). 2-year limited warranty.
Introduction Important: The C-Series controller cannot operate in more than one function at the same time. If several functions are required in a system, a dedicated controller must be used for each function. Charge Control Mode In the Charge Control mode, the C-Series controls how the batteries are charged by the DC source (solar, wind, or hydro). It uses a 3-stage charging protocol to maintain battery voltage at bulk and/or float levels.
Operating Modes Bulk Stage During this stage, the batteries are charged at the bulk voltage setting and maximum current output of the DC source. When the battery voltage reaches the bulk voltage setting, the controller activates the next stage (absorption). Absorption Stage During this stage, the voltage of the battery is held at the bulk voltage setting until an internal timer has accumulated one hour. Current gradually declines as the battery capacity is reached.
Introduction Battery Temperature Compensation The optional Battery Temperature Sensor (BTS) automatically adjusts the charging process of the C-Series controller. With the BTS installed, the C-Series will increase or decrease the battery charging voltage depending on the temperature of the battery to optimize the charge to the battery and maintain optimal performance of the battery.
Controller Functions Controller Functions The C-Series can be configured to function as three different controllers: • • • PV Charge Controller (Charge Control mode) Diversion Controller (Charge Control mode) Load Controller (Load Control mode) Photovoltaic Charge Controller The C-Series controller can operate as a Photovoltaic Charge Controller, also called a “series regulator”.
Introduction If the current from the PV array reaches 85 amps, the controller will turn off to protect the circuitry. In the event of a shutdown, the controller automatically resets itself after 10 minutes (if overcurrent condition is no longer present). See “Operating Mode Jumper” on page 20 for information on configuring this function.
Controller Functions Figure 1-4 Diversion Controller Diversion Loads Diversion control 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 available for the diversion of power at all times. Resistive-type heating elements are the best diversion loads. Special direct-current water heating elements are available.
Introduction 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 Current draw of the diversion load is very important. Problems may arise from operating with a load that is too small or too large.
Controller Functions or automatic reconnect when the C-Series is used as a load controller. Do not use this decal if using the C-Series controller as a PV Charge Controller or Diversion Controller. Low Voltage Disconnect When configured as a load controller, the C-Series controller will disconnect the load from the batteries when it reaches the LVD setting.
Introduction Potentiometer knobs Attach decal over potentiometers for Load Control Settings Figure 1-6 Decal Displaying Load Control Voltage Settings Optional Accessories The follow accessories can be purchased for use with the C-Series Multifunction DC Controller: • • Display Meters: The CM faceplate or CM/R remote display provide a digital display for monitoring the C-Series controller’s operation. The CM faceplate attaches directly to the front of the C-Series controller.
2 Installation Chapter 2 contains information and procedures to install C-Series Multifunction DC Controller.
Installation Pre-Installation The instructions that follow are applicable to the typical installation. For special applications, consult a qualified electrician or your Xantrex Certified Dealer. Installation procedures will vary according to your specific application. 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.
Pre-Installation knockouts before making any wiring connections. It is also recommended to use bushings or conduits to protect the wiring from damage from rough edges in the knockout holes.
Installation Mounting the Controller The C-Series controller is designed for indoor mounting. Care should be taken in selecting a location and when mounting the enclosure. Avoid mounting it in direct sunlight to prevent heating of the enclosure. The enclosure should be mounted vertically on a wall. In outdoor installations, the C-Series controller must be installed in a rainproof enclosure to eliminate exposure to rain, mist or water-spray.
Pre-Installation WARNING: Explosion/Corrosion Hazard Do not locate the C-Series controller in 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. If using “sealed” batteries, the controller can be mounted in the same enclosure as long as it is adequately ventilated. Place keyhole slots on the back of the controller over the mounting screws.
Installation Configuring the C-Series Controller Before making any wiring connections to the C-Series controller, it must be configured for the desired mode of operation. The following sections describe the how to configure the unit for the desired application and function. Jumper Settings Three sets of jumpers are located on the right side of the controller’s circuit board. These jumpers control equalization, low voltage reconnect, battery voltage, and operating modes.
Configuring the C-Series Controller Table 2-1 Factory Default Settings for C-Series Controllers Setting C35, C40 and C60 Battery Voltage 12 volts DC Equalize/LVR Manual Equalization Operating Mode Charge Control NiCad Setting Selection R46 Resistor Load Control Decal EQ/LVR Jumper Operating Mode Jumper Reset Switch Potentiometers Voltage Jumper Battery Temperature Sensor Port DC Terminal Connectors CM or CM/R Port Note: This photograph shows the Load Control Voltage decal installed on the circuit
Installation Operating Mode Jumper This jumper determines the operating mode. Place the jumper over the pins that correspond to the desired mode. • • Charge Control (PV Charge Controller or Diversion Controller) Load Control (Load Controller) Factory default setting is Charge Control mode. Charge/Load Control Jumper Charge Control Mode Load Control Mode Figure 2-6 Mode of Operation Jumper Voltage Jumper The voltage jumper determines the voltage of the system that the controller will be used with.
Configuring the C-Series Controller Automatic/Manual Battery Equalization (EQ) and Low Voltage Reconnect (LVR) Jumper Depending on the mode of operation chosen, this jumper enables: • • automatic or manual battery equalization (Charge Control mode), or automatic or manual reconnect in the event of low voltage event (Load Control mode). When AUTO is enabled in the Charge Control mode, the unit will perform an equalization charge every 30 days.
Installation Adjusting the C-Series Voltage Settings The charging voltage setpoints and voltage reconnect/ disconnect setting of the controller are adjustable using two rotary potentiometer controls. The knobs are removable to reduce the likelihood of accidental mis-adjustment if bumped. Calibrated scales, shown as scale marks, are provided to allow setting of the control without requiring the use of a digital voltmeter.
Adjusting the C-Series Voltage Settings For FLOAT charge voltage, the potentiometer scale is calibrated follows: • • • 14.6 14.8 14.4 12-volt system: 12.5 to 14.5 volts in increments of 0.2 volts, 24-volt system: 25.0 to 29.0 volts in increments of 0.4 volts, and 48-volt system: 50.0 to 58.0 volts in increments of 0.8 volts. 29.2 29.6 15.0 30.0 28.8 28.4 14.2 BULK (CHG) 28.0 BULK (CHG) 14.0 27.6 13.8 13.6 13.4 13.2 14.1 14.3 13.9 27.2 26.8 26.4 13.0 28.2 28.6 27.8 14.5 26.0 29.0 27.4 13.
Installation Setting Voltage Parameters for Load Control Mode To change the Low Voltage Disconnect (LVD) and Low Voltage Reconnect (LVR) settings, use the same BULK and FLOAT potentiometers. However, when the C-Series controller is used for DC Load Control, the potentiometer’s scale calibration is altered from what is printed on the circuit board.
Adjusting the C-Series Voltage Settings The scale for the Low Voltage Disconnect setting is calibrated as follows: • • • 13.6 13.8 13.4 12-volt system: 10.5 to 12.5 volts in increments of 0.2 volts, 24-volt system: 21.0 to 25.0 volts in increments of 0.4 volts, and 48-volt system: 42.0 to 50.0 volts in increments of 0.8 volts. 27.2 27.6 14.0 L.V.R (LOAD) LOW VOLTAGE RECONNECT 13.2 13.0 12.8 12.6 12.4 12.2 12.1 12.3 11.9 11.7 11.3 25.6 25.2 24.8 24.4 12.0 24.2 24.6 23.8 12.5 L.V.
Installation Setting Voltage Parameters Diversion Control Mode When the C-Series controller is configured for Diversion Control mode, you can set the voltage at which the unit begins diverting current to a diversion load (high voltage diversion). Use the Charge Control scale for setting this value. See Figure 2-10 on page 23 for Charge Control scale settings. The unit will continue diverting excess current to the diversion load until the source voltage falls to or below the BULK setting.
Adjusting the C-Series Voltage Settings 16.6 16.8 16.4 33.2 33.6 17.0 16.2 BULK (CHG) 32.0 BULK (CHG) 16.0 34.0 32.8 32.4 31.6 15.8 15.6 15.4 15.2 16.1 16.3 15.9 31.2 30.8 30.4 15.0 32.2 32.6 31.8 16.5 30.0 33.0 31.4 15.7 FLOAT (CHG) 31.0 FLOAT (CHG) 15.5 30.6 15.3 30.2 15.1 14.9 14.7 29.8 29.4 14.5 24-Volt System Settings 12-Volt System Settings 66.4 67.2 29.0 68.0 65.6 64.8 BULK (CHG) 64.0 63.2 62.4 61.6 60.8 64.4 65.2 63.6 60.0 66.0 62.8 FLOAT (CHG) 62.0 61.2 60.
Installation Using a Digital Voltmeter to Adjust Voltage Settings A digital DC voltmeter (DVM) can be used to provide a more accurate setting of voltage parameters. Test points are provided at the mid-range on the scales for this purpose. The potentiometers are equipped with removable knobs to prevent accidental mis-adjustments. If the knobs are missing, a 5/64" hex-head driver can be used to adjust the settings. To test and adjust the voltage setting using a DVM: 1.
Adjusting the C-Series Voltage Settings For example for a 48-volt system: To set BULK 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).
Installation Equalization Charging CAUTION: Damage to Batteries : Equalization should be done for standard electrolyte, vented batteries only. Sealed, GEL cell, or NiCad batteries should not be equalize-charged. Consult your battery supplier for details on equalize-charging for the battery type in your system. The C-Series offers either manual or automatic triggering of the equalization charging process.
Equalization Charging Manual Equalization Manual equalization of the battery can be enabled by pressing the Reset Switch on the right side of the C-Series until the status LED indicator begins to alternate between red and green. This could take about 10 seconds.
Installation Automatic Equalization The C-Series controller can automatically trigger an equalization charge every 30 days. The status LED will indicate that the equalization process is occurring. The equalization process will continue until the voltage has been held above the bulk setting for a cumulative period of two hours. This might take several days on larger systems with big batteries and small PV arrays.
Temperature Compensation Terminating the Equalization Process To 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 with a bulk charge cycle and then hold the battery at the bulk setting for one hour (the absorption stage) before returning to the float setting.
Installation Temperature Compensation Based on Battery Type The C-Series controller uses the battery type to determine the temperature compensated voltage settings. The temperature compensated charging voltage is normally based on a Lead – Acid types of battery. If using Alkaline-type batteries, the R46 resistor on the circuit board inside the controller will have been clipped as shown in “Setting Voltage Parameters for Alkaline Batteries” on page 26.
Temperature Compensation Table 2-2 Variances in Charging Voltage based on Battery Temperature Temperature (around the BTS) 12-volt units 24-volt units Lead Acid Lead Acid NiCad NiCad 48-volt units Lead Acid NiCad Celsius Fahrenheit (6 cells) (10 cells) (12 cells) (20 cells) (24 cells) (40 cells) 60 140 -1.05 -0.70 -2.10 -1.40 -4.20 -2.80 55 131 -0.90 -0.60 -1.80 -1.20 -3.60 -2.40 50 122 -0.75 -0.50 -1.50 -1.00 -3.00 -2.00 45 113 -0.60 -0.40 -1.20 -0.80 -2.40 -1.
Installation If using a BTS, when the battery temperature drops below 77°F (25 °C), the regulation voltage setting automatically increases. When the temperature rises above 77°F (25 °C) the regulation battery voltage setting automatically decreases. Manual Battery Temperature Compensation If no Battery Temperature Sensor (BTS) is installed and the batteries will be operating in very hot or very cold conditions, adjust the bulk and float settings to allow for the battery temperature.
Grounding Grounding The C-Series controller is designed to work with both negative ground and ungrounded electrical systems. The metal chassis of this charge/load controller must 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.
Installation Wiring 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 before wiring.
Wiring Terminal Torque Requirements Once the wires have been installed, torque the terminals as follows. Be careful not to overtighten.
Installation Minimum Recommended Wire Gauge The minimum recommended wire gauge is: • • C35 and C40 Models: #8 AWG with a 75 °C (167 °F) insulation rating C60 Models: #6 AWG, with a 90 °C (194 °F) insulation rating The terminals on the C-Series will accept up to #2 AWG (33.6 mm2) copper or aluminum wire. However, UL specifications only allow the use of up to #6 AWG (13.3 mm2) maximum. No crimp-on terminals or lugs are required. Size Diameter Size Diameter 14 12 .073 .072 1 .335 10 .115 1/0 .380 8 .
Wiring controller are strongly recommended. Put a surge protection device on the input line of the C-Series controller between the PV array and the controller. If the battery, is over 15 feet away from the controller, or if it is routed next to other wiring or sources of power, additional surge protection devices are recommended. Put the surge protection device for this scenario on the battery input line between the battery and the controller.
Installation Long-distance wire runs If there is a significant distance between the PV array and the controller and/or the controller and the battery, larger wires can be used to reduce the voltage drop and improve performance. Refer to Table 2-4. To use a larger size wire, use a splicer block (terminal block) intended for this purpose. This allows the larger cable size from the batteries to be “spliced” to the smaller wire size connected to the controller.
Wiring 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)a Distance in Feet (meters) 4 AWG 3 AWG 2 AWG 1 AWG 1/0 AWG 2/0 AWG 12 AWG 10 AWG 8 AWG 6 AWG 10 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. 70.9 ft. 89.6 ft. 112.5 ft. 141.7 ft. 225.8 ft. (17.10 m) (21.61 m) (27.
Installation PV Charge Control Mode Wiring The procedure below is illustrated in Figure 2-23. WARNING: Shock Hazard PV arrays generate voltage whenever light strikes the surface of the array. Before connecting the C-Series controller, cover or disconnect the array to prevent any current from being generated. To connect the C-Series controller as a charge controller: 1. Connect the PV array’s positive (+) output to the PV array disconnect. 2.
Wiring Battery Positive (+) Common PV Array Negatives Negative (–) Battery Negative (–) PV+ Array Positive (+) 4 3 7 1 2 8 5 6 A 9 A Ensure the proper grounding is in place for the entire system.
Installation Diversion Control Mode Wiring The procedure below is illustrated in Figure 2-24. When using the C-Series unit as a Diversion or DC Load Controller, the DC load needs to be connected to the controller terminals marked as PV +/LOAD+ and COMMON NEGATIVE. To connect the C-Series as a diversion load controller: 1. Connect your DC current source (PV, wind, hydro, etc.) directly to the RE disconnect. 2. Connect another cable from the other side of the RE disconnect to the battery positive terminal.
Wiring Common Negatives Battery Positive (+) Diversion Load Positive (+) Battery Negative (–) Diversion Load Negative (–) 1 4 8 6 7 2 3 5 A A Ensure the proper grounding is in place for the entire system.
Installation DC Load Control Mode Wiring The procedure below is illustrated in Figure 2-25. To connect the C-Series controller as a DC load controller: 1. Connect a cable from the BAT POSITIVE terminal on the controller to a battery disconnect. 2. Connect the positive battery cable to the battery disconnect. 3. Connect the negative battery cable to the one of the terminals marked COMMON NEGATIVES. 4.
Wiring Common Negatives Battery Positive (+) DC Load Positive (+) Battery Negative (–) 1 DC Load Negative (–) 3 5 4 2 Figure 2-25 Load Control Mode Wiring 975-0004-01-02 Rev D 49
Installation Installing Optional Accessories The following sections describe how to install the optional accessories available for the C-Series Multifunction DC Controller. Installing a Digital Display Follow the instructions in the C-Series Meter Displays Installation Guide 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.
Installing Optional Accessories Installing the Battery Temperature Sensor To install the BTS: 1. Install the BTS on the side of the battery below the electrolyte level. It is best to place the sensor between batteries and place 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.
Installation Reinstalling the Faceplate To reinstall the faceplace 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. Align these screw holes. Replace the phillips screws to secure the faceplate.
3 Operation Chapter 3 contains information about the operation of a C-Series Multifunction DC Controller.
Operation Basic Operation The C-Series controller (all models) has one multicolor LED status indicator and one reset button.
LED Status Indicator LED Status Indicator The multicolor LED on the base unit, or the optional CM faceplate or CM/R remote, indicates the operating status of the controller. A color-coded label is included on the cover of the controller explaining the status LED’s indications. • • • • When in Charge Control mode, the LED will be green. When in Load Control mode, the LED will be red. When an Error Condition exists or the load has disconnected, the LED will be orange.
Operation 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 >0.03 above LVD above LVD BULK Setting Minus (–) >0.45 above LVD LVD Setting Plus (+) 0.25 Vdc 0.50 Vdc 1.00 Vdc 4 blinks 0.15 Vdc 0.30 Vdc 0.45 Vdc 0.50 Vdc 1.00 Vdc 2.00 Vdc 3 blinks 0.30 Vdc 0.60 Vdc 0.90 Vdc 0.75 Vdc 1.50 Vdc 3.
LED Status Indicator For example, if the system battery voltage is 24 volts and the internal Bulk voltage setting is set for 28 volts, you can estimate how much below the Bulk setting the batteries are by subtracting the number in Table 3-1 (the internal Bulk setting). With the LED indicating three blinks, the battery voltage is approximately 27 volts (28 volts Bulk setting minus 1.00 volts in the table). With the LED indicating one blink, the battery voltage is somewhere below 26.
Operation Equalization Mode Indication (Red/green) Be sure to read all cautions and warning regarding equalization charging batteries BEFORE allowing an equalization charge to occur. Damage to batteries can occur. Alternating Red and Green The controller is in the EQUALIZE mode. It will automatically stop the equalization process after accumulating two hours of operation at a voltage above the BULK setting.
LED Status Indicator Error Mode Indication (Orange) The C-Series Multifunction DC Controller error modes include the following. • • • Over-temperature Condition - fast flash Over-current Condition - fast flash Low-Voltage Disconnect Condition (Load Control Mode) - slow flash Over-temperature Condition The temperature of the controller’s transistors is continuously monitored. This protects the charge controller from damage in high temperature environments.
Operation Fast Blinking Orange When the over-current or over-temperature protection system has caused the controller to shutdown, the status LED will be orange and will blink fast (about once a second). Low-voltage Disconnect Condition If voltage remains below the LVD setting, the unit will disconnect after a 6-minute “delay” (or “grace”) period. To reset and reconnect for another “grace” period (approximately 6 minutes), press and release the reset switch.
Reset Switch Important: The LED will light red only in Load Control mode; never in Charge or Diversion mode (unless it is reversed upon reinstallation). Reset Switch Use the Reset Switch on the side of the chassis for the following conditions. • • • • To manually initiate battery equalization in Charge Control mode, press and hold the Reset Switch until the red and green LED start to flash.
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4 Troubleshooting Chapter 4, “Troubleshooting” contains information about identifying and resolving possible problems with systems using a C-Series Multifunction DC Controller.
Troubleshooting PV Charge Control Troubleshooting The following table lists possible problems that may arise when using the C-Series Multifunction DC Controller as a PV Charge Controller. Table 4-1 PV Charge Control Problems Problem Possible Cause Solution Controller is overcharging battery (verified by measured current through the controller). PV positive and Battery positive wires have been swapped. Verify the voltage on PV terminal and Battery terminal are from the correct sources.
PV Charge Control Troubleshooting Table 4-1 PV Charge Control Problems Problem Possible Cause Solution Current uneven between multiple controllers. A. Solar arrays are supplying different amounts of current to each charge controller. B. Charging set points are not all set the same. C. Excess voltage drop in wiring causing controllers to measure the battery voltage differently and regulate accordingly. D. Accuracy of the controllers may vary between controllers, due to tolerances in meter design. A.
Troubleshooting Diversion Control Troubleshooting The following table lists possible problems that may arise when using the C-Series Multifunction DC Controller as a Diversion Controller. Table 4-2 Diversion Control Problems Problem Possible Cause Solution Status LED Blinks Orange after switching on diversion load breaker or when diversion begins (Bulk or Float settings reached). Diversion load draws too much current (above controller rating).
Diversion Control Troubleshooting Table 4-2 Diversion Control Problems Problem Possible Cause Solution Diversion load operates while a generator (fuel powered) is running. Bulk Voltage setting on diversion controller is set too close to other charger 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.
Troubleshooting Load Control Troubleshooting The following table lists possible problems that may arise when using the C-Series Multifunction DC Controller as a Load Controller. Table 4-3 Load Control Problems Problem Possible Cause Solution Load disconnects at different point than set for. A. Load Control 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.
A Specifications Appendix A, “Specifications” provide the specifications for the C-Series Multifunction DC Controller.
Specifications Electrical Specifications The following lists the electrical specifications for the C-Series controllers Models C35, C40, and C60.
Features and Options Specifications Table A-1 Electrical Specifications Model C35 C40 C60 Load Control Settings: System Voltage: Low Voltage Reconnect Low Voltage Disconnect 12 Volt System: 24 Volt System: 48 Volt System: LVR 12.0 to 14.0 Vdc LVR 24.0 to 28.0 Vdc LVR 48.0 to 56.0 Vdc LVD 10.5 to 12.5 Vdc LVD 21.0 to 25.0 Vdc LVD 42.0 to 50.0 Vdc Features and Options Specifications The following lists the features and options specifications for the C-Series controllers Models C35, C40, and C60.
Specifications Environmental Specifications The following lists the environmental specifications for the C-Series controllers Models C35, C40, and C60. Table A-3 Environmental Specifications Model C35 C40 C60 Enclosure Type Indoor, ventilated, powder-coated steel with 3/4" and 1" knockouts.
B Batteries Appendix B, “Batteries” describes types of batteries.
Batteries Battery Types Batteries come in different sizes, types, amp-hour capacity, voltages and chemistries. Here are a few guidelines that will help in battery selection, and ensure that the batteries are properly maintained. The best source of the most appropriate settings for the C-Series will be from the manufacturer or supplier of the batteries. WARNING: Explosion/Corrosion Hazard Batteries can vent hydrogen-sulfide gas, which is corrosive to electronic equipment.
Battery Types 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.
Batteries NiCad and NiFe Batteries The Xantrex C-Series is compatible with NiCad (nickel-cadmium) NiFe (nickel-iron) and alkaline-type batteries, which must be charged to a higher voltage level to achieve a full charge. To use the C-Series with NiCad batteries, clip the wire on the resistor labeled “R46” in the middle of the C-Series circuit board by cutting it. See “Setting Voltage Parameters for Alkaline Batteries” on page 26 for instructions on how to clip this wire.
Equalization Charging Equalization Charging Approximately every month, some batteries may need to be “equalized.” Since the individual cells of the battery are not identical, some cells may not be fully charged when the charging process is completed. If the batteries have been left in a discharged condition for long periods of time, the plates will have sulfates on them from the electrolyte.
Batteries CAUTION: Damage to Batteries Equalization should be done only on vented (not sealed or maintenance-free) lead-acid, liquid-electrolyte batteries. The battery manufacturer should be consulted before attempting to equalize any other battery type. Add clean, distilled water to the battery following the equalization process.
Equalization Charging Equalization Setpoints (Non-Sealed Batteries Only) Table B-1 Typical Bulk and Float Setpoints for Batteries Battery Type Bulk Volts Float Volts Equalizing Charge Default Settings (knobs 14.0 Vdc at nine o’clock position) 13.5 Vdc Disabled (manual jumper) Sealed Gel Lead Acid Battery 14.1 Vdc 13.6 Vdc Non recommended. Consult Battery manufacturer. AGM Lead Acid Battery 14.4 Vdc 13.4 Vdc Charge to 15.5 Vdc or per manufacturer. Maintenance-Free RV/Marine 14.4 Vdc 13.
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C Diversion Loads Appendix C, “Diversion Loads” provides additional information about Diversion Loads.
Diversion Loads Diversion Load Types Several different types of diversion loads are available to the alternative energy market. These loads are designed to operate with the power output levels common to most diversion load controllers. The following are several available diversion loads which may be used successfully for heating water or air.
Diversion Load Types Regardless of the type of diversion load you decide to utilize, make sure that the diversion load can handle all the power the charging system is capable of putting out. Paralleling heater elements (whether open air or water heater) will allow more power dissipation. A good rule of thumb is to not have a combined charging source greater than 80% of the diversion load controller’s current handling ability.
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Warranty and Product Information Warranty What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc. ("Xantrex") and covers defects in workmanship and materials in your CSeries Multifunction DC Controller. This warranty period lasts for two years from the date of purchase at the point of sale to you, the original end user customer. You require proof of purchase to make warranty claims.
Warranty and Product Information Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your product manual. For some products, Xantrex maintains a network of regional Authorized Service Centers. Call Xantrex or check our website to see if your product can be repaired at one of these facilities.
Return Material Authorization Policy PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY.
Warranty and Product Information Return Procedure 1. Package the unit safely, preferably using the original box and packing materials. Please ensure that your product is shipped fully insured in the original packaging or equivalent. This warranty will not apply where the product is damaged due to improper packaging. 2. Include the following: • The RMA number supplied by Xantrex Technology, Inc. clearly marked on the outside of the box. • A return address where the unit can be shipped.
Information About Your System Information About Your System As soon as you open your C-Series Multifunction DC Controller package, record the following information and be sure to keep your proof of purchase. ❐ Serial Number (on DC end) _______________________________ ❐ Purchased From _______________________________ ❐ Purchase Date _______________________________ If you need to contact Customer Service, please record the following details before calling.
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Index A I B J Accessories 12 Automatic Equalization 32 Battery Safety Information viii Battery Temperature Compensation 6 Battery Temperature Sensor 12, 51 BULK charge voltage 22 C Charge Control or Diversion Control Mode Indications 59 Customer Service preparing to call 89 D Diversion Control Mode 8, 26 E EQ/LVR Jumper 21 Equalization Charging 30 Equalization Mode Indication 57 Error Mode Indication 59 Information about Your System form 89 Jumper Settings 18 K Knockouts 14 L LED Status Ind
Index R Reset Switch 59 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 92 975-0004-01-02 Rev D
Xantrex 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.
