Windy-nation Xantrex C Series Multifunction DC Controller User Manual

www.xantrex.comSmart choice for powerC-Series Multifunction DC ControllerManual TypeC35C40C60Owner’s Manual

Safetyviii 975-0004-01-02 Rev DBattery Safety Information• Always wear eye protection, such as safety glasses, when working with batteries.• Remove al

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CDiversion LoadsAppendix C, “Diversion Loads” provides additional information about Diversion Loads.For information on: See:“Diversion Load Types” pag

Diversion Loads82 975-0004-01-02 Rev DDiversion Load TypesSeveral different types of diversion loads are available to the alternative energy market. T

Diversion Load Types975-0004-01-02 Rev D 83Regardless of the type of diversion load you decide to utilize, make sure that the diversion load can handl

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85Warranty and Product InformationWarrantyWhat does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc. ("Xantrex&

Warranty and Product Information86 975-0004-01-02 Rev DDirect returns may be performed according to the Xantrex Return Material Authorization Policy d

Return Material Authorization Policy975-0004-01-02 Rev D 87PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHAL

Warranty and Product Information88 975-0004-01-02 Rev DReturn Procedure1. Package the unit safely, preferably using the original box and packing mater

Information About Your System975-0004-01-02 Rev D 89Information About Your SystemAs soon as you open your C-Series Multifunction DC Controller package

Battery Safety Information975-0004-01-02 Rev D ixCAUTION:A battery can produce the following hazards to personal safety:• electrical shock, • burn fro

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Accessories 12Automatic Equalization 32Battery Safety Information viiiBattery Temperature Compensation 6Battery Temperature Sensor 12, 51BULK charge v

Index92 975-0004-01-02 Rev DReset Switch 59Safety Instructions viiserial number 89Test Points for Voltage Settings 28Torque Requirements 39Troublshoot

Xantrex Technology Inc.1 800 670 0707 Tel toll free NA1 360 925 5097 Tel direct1 800 994 7828 Fax toll free NA1 360 925 5143 Fax directcustomerservice

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xiImportant Safety Instructions - - - - - - - - - - - - - - - - - -vii1IntroductionFeatures - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Contentsxii 975-0004-01-02 Rev DAutomatic/Manual Battery Equalization (EQ) and Low Voltage Reconnect (LVR) Jumper - - - - - - - - - - - - - - 21Adjus

Contents975-0004-01-02 Rev D xiii3OperationBasic Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54LED Status Indicator

Contentsxiv 975-0004-01-02 Rev DBattery Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76Equalization Charging- - - - -

xvFigure 1-1 C-Series Multifunction DC Charge Controllers - - - - - - 2Figure 1-2 3-stage Battery Charging Process - - - - - - - - - - - - - - - 5Fi

Figuresxvi 975-0004-01-02 Rev DFigure 2-22 AWG Wire Gauge Reference Chart - - - - - - - - - - - - - 40Figure 2-23 PV Charge Control Mode Wiring - -

xviiTable 2-1 Factory Default Settings for C-Series Controllers- - - - 19Table 2-2 Variances in Charging Voltage based on Battery Temperature - - - -

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1IntroductionChapter 1 describes features and functions of the C-Series Multifunction DC Controller.For information on: See:“Features” page 2“Operatin

Introduction2 975-0004-01-02 Rev DFeaturesThe C35/C40/C60 (C-Series) controllers can be used with 12-volt, 24-volt, or 48-volt DC systems (depending u

Operating Modes975-0004-01-02 Rev D 3• Indoor-type, powder-coated enclosure, for wall mounting.• Conformal-coated circuit boards, plated terminals, po

Introduction4 975-0004-01-02 Rev DCharge Control ModeIn the Charge Control mode, the C-Series controls how the batteries are charged by the DC source

Operating Modes975-0004-01-02 Rev D 5Bulk StageDuring this stage, the batteries are charged at the bulk voltage setting and maximum current output of

Introduction6 975-0004-01-02 Rev DBattery Temperature Compensation The optional Battery Temperature Sensor (BTS) automatically adjusts the charging pr

Controller Functions975-0004-01-02 Rev D 7Controller FunctionsThe C-Series can be configured to function as three different controllers:• PV Charge Co

Introduction8 975-0004-01-02 Rev DIf the current from the PV array reaches 85 amps, the controller will turn off to protect the circuitry. In the even

Controller Functions975-0004-01-02 Rev D 9Diversion LoadsDiversion control requires a separate “dump” load to regulate the battery. This load must be

C-Series Multifunction DC ControllerOwner’s Guide

Introduction10 975-0004-01-02 Rev DLoad ControllerThe C-Series controller can operate as a Low Voltage Disconnect (LVD) for DC loads to prevent over-d

Controller Functions975-0004-01-02 Rev D 11or automatic reconnect when the C-Series is used as a load controller. Do not use this decal if using the C

Introduction12 975-0004-01-02 Rev DOptional AccessoriesThe follow accessories can be purchased for use with the C-Series Multifunction DC Controller:•

2InstallationChapter 2 contains information and procedures to install C-Series Multifunction DC Controller.For information on: See:“Pre-Installation”

Installation14 975-0004-01-02 Rev DPre-InstallationThe instructions that follow are applicable to the typical installation. For special applications,

Pre-Installation975-0004-01-02 Rev D 15knockouts before making any wiring connections. It is also recommended to use bushings or conduits to protect t

Installation16 975-0004-01-02 Rev DMounting the ControllerThe C-Series controller is designed for indoor mounting. Care should be taken in selecting a

Pre-Installation975-0004-01-02 Rev D 17If using “sealed” batteries, the controller can be mounted in the same enclosure as long as it is adequately ve

Installation18 975-0004-01-02 Rev DConfiguring the C-Series ControllerBefore making any wiring connections to the C-Series controller, it must be conf

Configuring the C-Series Controller975-0004-01-02 Rev D 19Table 2-1Factory Default Settings for C-Series ControllersSetting C35, C40 and C60Battery Vo

About XantrexXantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to

Installation20 975-0004-01-02 Rev DOperating Mode JumperThis jumper determines the operating mode. Place the jumper over the pins that correspond to t

Configuring the C-Series Controller975-0004-01-02 Rev D 21Automatic/Manual Battery Equalization (EQ) and Low Voltage Reconnect (LVR) JumperDepending o

Installation22 975-0004-01-02 Rev DAdjusting the C-Series Voltage SettingsThe charging voltage setpoints and voltage reconnect/ disconnect setting of

Adjusting the C-Series Voltage Settings975-0004-01-02 Rev D 23For FLOAT charge voltage, the potentiometer scale is calibrated follows: • 12-volt syste

Installation24 975-0004-01-02 Rev DSetting Voltage Parameters for Load Control ModeTo change the Low Voltage Disconnect (LVD) and Low Voltage Reconnec

Adjusting the C-Series Voltage Settings975-0004-01-02 Rev D 25The scale for the Low Voltage Disconnect setting is calibrated as follows:• 12-volt syst

Installation26 975-0004-01-02 Rev DSetting Voltage Parameters Diversion Control ModeWhen the C-Series controller is configured for Diversion Control m

Adjusting the C-Series Voltage Settings975-0004-01-02 Rev D 27Figure 2-14Voltage Settings with R46 Resistor ClippedCAUTION: Damage to BatteriesIt is n

Installation28 975-0004-01-02 Rev DUsing a Digital Voltmeter to Adjust Voltage SettingsA digital DC voltmeter (DVM) can be used to provide a more accu

Adjusting the C-Series Voltage Settings975-0004-01-02 Rev D 29For example for a 48-volt system: To set BULK voltage to 56.4 volts:1. Point the BULK po

iiiAbout This GuidePurposeThe purpose of this Guide is to provide explanations and procedures for installing, operating, maintaining, and troubleshoot

Installation30 975-0004-01-02 Rev DEqualization ChargingThe C-Series offers either manual or automatic triggering of the equalization charging process

Equalization Charging975-0004-01-02 Rev D 31Manual EqualizationManual equalization of the battery can be enabled by pressing the Reset Switch on the r

Installation32 975-0004-01-02 Rev DAutomatic EqualizationThe C-Series controller can automatically trigger an equalization charge every 30 days. The s

Temperature Compensation975-0004-01-02 Rev D 33Terminating the Equalization ProcessTo stop the equalization process, press the reset switch on the rig

Installation34 975-0004-01-02 Rev DTemperature Compensation Based on Battery TypeThe C-Series controller uses the battery type to determine the temper

Temperature Compensation975-0004-01-02 Rev D 35Table 2-2Variances in Charging Voltage based on Battery Temperature Temperature(around the BTS) 12-volt

Installation36 975-0004-01-02 Rev DIf using a BTS, when the battery temperature drops below 77°F (25 °C), the regulation voltage setting automatically

Grounding975-0004-01-02 Rev D 37GroundingThe C-Series controller is designed to work with both negative ground and ungrounded electrical systems. The

Installation38 975-0004-01-02 Rev DWiringDC Terminal Connector LocationsTerminal connectors for DC wiring are located on the lower edge of the circuit

Wiring975-0004-01-02 Rev D 39Terminal Torque RequirementsOnce the wires have been installed, torque the terminals as follows. Be careful not to overti

About This Guideiv 975-0004-01-02 Rev DChapter 2 contains information and procedures to install C-Series Multifunction DC Controller.Chapter 3 contain

Installation40 975-0004-01-02 Rev DMinimum Recommended Wire GaugeThe minimum recommended wire gauge is:• C35 and C40 Models: #8 AWG with a 75 °C (167

Wiring975-0004-01-02 Rev D 41controller are strongly recommended. Put a surge protection device on the input line of the C-Series controller between t

Installation42 975-0004-01-02 Rev DLong-distance wire runsIf there is a significant distance between the PV array and the controller and/or the contro

Wiring975-0004-01-02 Rev D 43Table 2-4One-Way Wire Distance and Wire SizeMaximum One-way Wire Distance for a < 3% Voltage drop12 Vdc Application Sh

Installation44 975-0004-01-02 Rev DPV Charge Control Mode WiringThe procedure below is illustrated in Figure 2-23.To connect the C-Series controller a

Wiring975-0004-01-02 Rev D 45Figure 2-23PV Charge Control Mode Wiring4217568A39ABattery Positive (+)PV+ Array Positive (+)PV Array Negative (–)Battery

Installation46 975-0004-01-02 Rev DDiversion Control Mode WiringThe procedure below is illustrated in Figure 2-24.When using the C-Series unit as a Di

Wiring975-0004-01-02 Rev D 47Figure 2-24Diversion Control Mode Wiring4217568A3Ensure the proper grounding is in place for the entire system.ABattery P

Installation48 975-0004-01-02 Rev DDC Load Control Mode WiringThe procedure below is illustrated in Figure 2-25.To connect the C-Series controller as

Wiring975-0004-01-02 Rev D 49Figure 2-25Load Control Mode Wiring42153Battery Positive (+)DC Load Positive (+)DC Load Negative (–)Battery Negative (–)C

About This Guide975-0004-01-02 Rev D vAbbreviations and AcronymsRelated InformationYou can find more information about Xantrex Technology Inc. as well

Installation50 975-0004-01-02 Rev DInstalling Optional AccessoriesThe following sections describe how to install the optional accessories available fo

Installing Optional Accessories975-0004-01-02 Rev D 51Installing the Battery Temperature SensorTo install the BTS:1. Install the BTS on the side of th

Installation52 975-0004-01-02 Rev DReinstalling the FaceplateTo reinstall the faceplace on the C-Series controller:1. Align faceplate with front of ch

3OperationChapter 3 contains information about the operation of a C-Series Multifunction DC Controller.For Information on: See:“Basic Operation” page

Operation54 975-0004-01-02 Rev DBasic OperationThe C-Series controller (all models) has one multicolor LED status indicator and one reset button. Figu

LED Status Indicator975-0004-01-02 Rev D 55LED Status IndicatorThe multicolor LED on the base unit, or the optional CM faceplate or CM/R remote, indic

Operation56 975-0004-01-02 Rev DCharge Control or Diversion Control Indications (Green)The flashing rate of the LED indicates the controller’s stage o

LED Status Indicator975-0004-01-02 Rev D 57For example, if the system battery voltage is 24 volts and the internal Bulk voltage setting is set for 28

Operation58 975-0004-01-02 Rev DEqualization Mode Indication (Red/green)Be sure to read all cautions and warning regarding equalization charging batte

LED Status Indicator975-0004-01-02 Rev D 59Error Mode Indication (Orange)The C-Series Multifunction DC Controller error modes include the following.•

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Operation60 975-0004-01-02 Rev DFast Blinking Orange When the over-current or over-temperature protection system has caused the controller to shutdown

Reset Switch975-0004-01-02 Rev D 61Reset Switch Use the Reset Switch on the side of the chassis for the following conditions.• To manually initiate ba

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4TroubleshootingChapter 4, “Troubleshooting” contains information about identifying and resolving possible problems with systems using a C-Series Mult

Troubleshooting64 975-0004-01-02 Rev DPV Charge Control TroubleshootingThe following table lists possible problems that may arise when using the C-Ser

PV Charge Control Troubleshooting975-0004-01-02 Rev D 65Current uneven between multiple controllers.A. Solar arrays are supplying different amounts of

Troubleshooting66 975-0004-01-02 Rev DDiversion Control TroubleshootingThe following table lists possible problems that may arise when using the C-Ser

Diversion Control Troubleshooting975-0004-01-02 Rev D 67Diversion load operates while a generator (fuel powered) is running.Bulk Voltage setting on di

Troubleshooting68 975-0004-01-02 Rev DLoad Control TroubleshootingThe following table lists possible problems that may arise when using the C-Series M

ASpecificationsAppendix A, “Specifications” provide the specifications for the C-Series Multifunction DC Controller.For information on: See:“Electrica

975-0004-01-02 Rev D viiImportant Safety InstructionsGeneral Safety Instructions• All electrical work must be done in accordance with local, national,

Specifications70 975-0004-01-02 Rev DElectrical SpecificationsThe following lists the electrical specifications for the C-Series controllers Models C3

Features and Options Specifications975-0004-01-02 Rev D 71Features and Options SpecificationsThe following lists the features and options specificatio

Specifications72 975-0004-01-02 Rev DEnvironmental SpecificationsThe following lists the environmental specifications for the C-Series controllers Mod

BBatteriesAppendix B, “Batteries” describes types of batteries.For information on: See:“Battery Types” page 74“Battery Sizing” page 76“Equalization Ch

Batteries74 975-0004-01-02 Rev DBattery TypesBatteries come in different sizes, types, amp-hour capacity, voltages and chemistries. Here are a few gui

Battery Types975-0004-01-02 Rev D 75Vented batteries usually have battery caps. The caps may appear to be sealed, but are not. The caps should be remo

Batteries76 975-0004-01-02 Rev DNiCad and NiFe BatteriesThe Xantrex C-Series is compatible with NiCad (nickel-cadmium) NiFe (nickel-iron) and alkaline

Equalization Charging975-0004-01-02 Rev D 77Equalization ChargingApproximately every month, some batteries may need to be “equalized.” Since the indiv

Batteries78 975-0004-01-02 Rev DCAUTION: Damage to BatteriesEqualization should be done only on vented (not sealed or maintenance-free) lead-acid, liq

Equalization Charging975-0004-01-02 Rev D 79Equalization Setpoints (Non-Sealed Batteries Only) Table B-1Typical Bulk and Float Setpoints for Batteries