TrakMax40 Owners Manual
Contents
1. 1 Switch positions 0 and 1 are for monthly battery maintenance only Return the switch to the appropriate position for the system s batteries when Equalize charging has completed NEVER EQUALIZE GEL BATTERIES 2 Equalize voltages are displayed in the table with an asterisk Switch positions O and 1 only 3 Switch position 7 represents the default values as shipped from the factory 4 Always refer to the battery manufacturer s specifications for equalization 5 LED INDICATORS The TrakMax has one multicolor LED and one green LED to indicate the operating status of the controller a ee ee Page 16 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 windunation dsanjpower te the people TrakMax 40 MPPT charge contro ler A ed Single Color LED Multi Color LED A solid green LED indicates the charging source is functioning properly A flashing green LED indicates an error condition exists The multi color LED indicates the particular operating mode and the battery capacity level 5 1 CHARGE CONTROL Battery Capacity eee aL LED Indication 5 2 LED MODES Figure 5 1 Battery Capacity LED indicators If the single color LED or multi color LED flashes it indicates an error condition such as over temperature over current low voltage disconnect reverse connection for solar modules and over voltage of load The green LED s flash time2. 1 0 e Equalize During an equalization cycle the charging voltage will be held constant at the specified voltage setting 12 Volt 24 Volt Charge Function Float Bulk Float Bulk Switch Stage Equalize Stage Equalize Position Battery Type Volts Volts Volts Volts Equalize charge rate Time Battery Capacity 0 Equalize 1 13 2 15 26 4 30 6 hrs Min 12 hrs Max Equalize Rate Battery Capacity A hrs 40 Battery Charger Rate 1 Equalize 2 13 2 15 5 26 4 31 6 hrs Min 12 hrs Max Charger Rate Set by Battery Rate control Additional Float and Bulk settings for deep 13 3 15 26 6 30 cycle lead acid batteries Refer to battery manufacturer for settings Deep Cell Lead Acid 2 Additional setting of Bulk and Float voltages 3 ap pec 136 K Se Sc Refer to battery manufacturer for settings Recommended for gel cell batteries that 4 Gel Cell 2 13 7 14 4 27 4 28 8 specify high float voltages Refer to battery manufacturer for settings 5 Gel Cell 1 13 5 14 1 27 28 2 Typical gel cell battery setting 6 PcCa Lead 13 2 14 3 26 4 28 6 Recommended for use with sealed type car Calcium batteries 7 Deep Cycle Factory Default Setting Default Lead Acid 1 a P a eg 2 Typical deep cycle lead acid batteries 8 NiCad 1 14 16 28 32 Use for NiCad battery systems Recommended for use with nickel iron 9 NiCad 2 14 5 16 29 32 Fe adies Important
3. VOC greater than 55 VDC For 12 volt battery charging the open circuit voltage of the PV array must be between 12 30VDC For 24 volt battery charging the open circuit voltage of the PV array must be between 30 55VDC VV WV Important Installations should meet all local codes and standards Installations of this equipment should only be performed by skilled personnel such as licensed electricians and Certified Renewable Energy RE System Installers 3 1 ELECTROSTATIC ESD PRECAUTIONS All electronic circuits may be damaged by static electricity To minimize the likelihood of electrostatic damage discharge yourself by touching an electrical ground e g copper pipe prior to handling the unit and avoid touching components on the circuit boards The risk of electrostatic damage is highest when relative humidity is below 40 3 2 MOUNTING The mounting location is important to the performance and operating life of the controller The environment must be dry and protected from water If required the controller may be installed in a ventilated enclosure with sufficient airflow Never install the TrakMax MPPT in a sealed enclosure The controller may be mounted in an enclosure with sealed batteries but never with vented flooded batteries Battery fumes from vented batteries will corrode and destroy the TrakMax MPPT circuits 1 Place the TrakMax on a vertical surface protected from direct sun high temperatures and water The TrakMax requires
4. a combination of cool ambient temperature and low battery voltage The unit delivers the greatest charge current increase when you need it most in cold weather with a discharged battery Additionally anything that can be done to lower PV array temperature will also lead to increased charge current by increasing PV power production In cool comfortable temperatures and typical battery states of charge most systems see about 10 20 increase Charge current increase can go to zero in hot temperatures whereas charge current increase can easily exceed 30 with a discharged battery and freezing temperatures Module Te 25C 120 MPPT controller operates PV modele at max power point 5 extracting full 85W 800W m 80 Gester Si SS Typical contre ro charging at 12 extracts 65W 40 Current A aD Power W Current vs Voltage Power vs Voltage 0 5 10 15 20 25 Voltage V Figure 4 1 Current Power vs Voltage Characteristics 4 1 1 How MPPT Works A PV module is a constant current type device As shown on a typical PV module voltage vs current curve current remains relatively constant over a wide range of voltage A typical 75 watt module is specified to deliver 4 45 amps 17 volts 25 C cell temperature Conventional PV controllers essentially connect the PV array directly to the battery when the battery is discharged When a 75 watt PV module is connected directly to a battery charging at 12 volts the PV module st
5. charging Charge current or PV current is Check battery voltage current is reduced if battery voltage is at set points lower than expected e Check atmospheric haze dirty PV s or sun low on horizon etc e Check PV voltage if system has been changed from 24VDC to 12VDC or vice versa battery and PV power must be momentarily disconnected from the TrakMax to reboot the unit and load initial 12 or 24VDC control values TrakMax considers the PV array to be configured for 24VDC battery charging if PV voltage ever goes above 30VDC Charge OFF at high temperature The system temporarily shuts down due to high heat sink temperatures Improve ventilation or reduce PV power to prevent over temp shut down 6 3 SUPPORT If you are experiencing technical problems and cannot find a solution in this manual you can contact Windy Nation Inc for further assistance e Call 805 323 6445 e Email info windynation com e Write 1082 Front Street Unit B Ventura CA 93001 For challenging issues or to just ask a question consider using our FREE Community Forums Consult our community of DIY ers for fast answers to all your questions Post on our Forums http www windynation com community 7 BATTERIES 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
6. depends on the condition or function they are displaying See table 5 2 Single Color LED Multi Color LED Operation On Off State On Off Description Mode 1 Charge ON PV gt BV BAT lt LVD 2 Charge ON PV gt BV LVD lt BAT lt LVR NORMAL 3 Charge ON PV gt BV BAT gt LVR 4 Charge ON PV gt BV BAT lt LVD 5 Charge ON PV gt BV LVD lt BAT lt LVR DERATED 6 Charge ON PV gt BV BAT gt LVR 7 BAT under voltage 8 6s 00 Over Current 6s Off Over Temperature 6s J Off co f Over Voltage of Load 1s 1s 1s PV over voltage FAULT 1s 1s 1s IDN under voltage 6s co co BAT over voltage SCAS ee of range Table 5 2 Error Mode Indications NOTE When the controller is charging the green LED will be solid green Page 17 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 5 2 1 Low Voltage Disconnect LVD When a DC load is connected if voltage remains below the Low Voltage Disconnect setting the controller will disconnect after a 6 minute delay period The controller will wait until the voltage rises above the Low Voltage Reconnect setting 5 2 2 Over Voltage of Load If the controller detects an over voltage of load it will disconnect the load 5 2 3 Over Temperature The temperature of the controller s transistors is continuously monitored This protects the charge controller from damage in
7. manufacturer s recommendations 6 2 TROUBLESHOOTING Problem Possible Remedies No LED indications controller e Check the voltage at the battery terminals on the TrakMax Battery voltage does not appear to be powered must be a constant 12 VDC or greater If no voltage is measured check wiring connections fuses and breakers e f the voltage on the battery terminals of the controller is between 12 and 36 VDC and no LEDs are lit contact your dealer for service Charge status LED on but no Is the battery voltage greater than the charge voltage set point This is output charge current normal operation Output is off due to high battery voltage which may be caused by other charging systems e Battery voltage must be at least 9VDC for the unit to operate Unit is on but charge status Check PV connections for reverse polarity LED is off e PV must supply at least 0 25Amp at 3V more than battery voltage to begin charge e PV amp BAT must be separate for proper operation PV must receive earth ground via shunts inside the TrakMax which internally connect PV to BAT External connection prevents proper operation of internal shunts and current measurement system Battery voltage is determined BEE Page 18 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 automatically when the unit first receives power PV open circuit voltage must be 12 30VDC for 12VDC battery charging and 30 55VDC for 24VDC battery
8. take care not to damage the plugs when the cables are pulled through conduit WARNING Shock Hazard Never route network cables in the same conduit as the power conductors 3 9 BATTERY TEMPERATURE SENSOR BTS The charge voltage required by batteries changes with battery temperature Temperature compensation of the charge voltage enhances battery performance and life and decreases battery maintenance Automatic temperature compensation can be provided through use of the optional battery temperature sensor included Table 3 9 describes approximately how much the voltage may vary depending on the temperature of the batteries 3 9 1 Temperature Compensation Temperature 12 Volt Units 24 Volt Units Lead Acid NiCad Lead Acid NiCad Celsius Fahrenheit 6 cells 10 cells 12 cells 20 cells 60 140 1 05 0 7 2 1 1 4 55 131 0 9 0 6 1 8 1 2 50 122 0 75 0 5 1 5 1 45 113 0 6 0 4 1 2 0 8 40 104 0 45 0 3 0 9 0 6 35 95 0 3 0 2 0 6 0 4 30 86 0 15 0 1 0 3 0 2 25 77 0 0 0 0 20 68 0 15 0 1 0 3 0 2 15 59 0 3 0 2 0 6 0 4 10 50 0 45 0 3 0 9 0 6 5 41 0 6 0 4 1 2 0 8 0 32 0 75 0 5 1 5 1 5 23 0 9 0 6 1 8 1 2 10 14 1 05 0 7 2 1 1 4 15 5 1 2 0 8 2 4 1 6 20 4 1 35 0 9 2 7 1 8 25 13 1 5 1 3 2 30 22 1 65 1 1 3 3 2 2 35 31 1 8 1 2 3 6 2 4 40 40 1 95 1 3 3 9 2 6 Table 3 9 Variances in charging voltage based on battery temperature Temperature compensation is based on battery type 5m
9. the most appropriate settings for the TrakMax will be from the manufacturer or supplier of the batteries 7 1 BATTERY TYPES 7 1 1 Automotive Batteries Automotive and truck batteries are designed for high cranking power not deep cycling Do not use them unless no other battery type is available They simply will not last long in a cycling application 7 1 2 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 7 1 3 Deep Cycle Batteries Best suited for use with PV systems this type of battery is designed to be more deeply discharged before being recharged Deep cycle batteries are available in many sizes and types The most common is the vented liquid electrolyte battery Vented batteries usually have battery caps The caps may appear to be sealed but are not The caps should be removed periodically to check the level of electrolyte When a cell is low distilled water should be added after the battery is fully charged If the level is extremely low add only enough distilled water to cover the plates before recharging The electrolyte volume increases during the charging process and the battery will overflow if it is filled all of the way up before recharging Use only distilled water because impurities will reduce battery performance A popula
10. 3 4 VDC Limited Only if water level can be checked a Page 20 of 20 windynation 03 06 2013
11. 6 2013 TrakMax 40 User Manual Revision 1 0 4 2 2 Three Stage Charge The TrakMax is configured for a three stage charging process Bulk Absorption and Float The three stage charge process provides a somewhat higher charge voltage to charge the battery quickly and safely Once the battery is fully charged a somewhat lower voltage is applied to maintain the battery in a fully charged state without excessive water loss The three stage charge process charges the battery as quickly as possible while minimizing battery water loss and maintenance Bulk Stage Absorption Stage Float Stage Charging Buk Voks Setting Absorption Time Poar Vois Setting DC Voltage Constant Voltage Reduced VoRage Dc Current O amps Time 4 2 2 1 Bulk Stage When charge starts the TrakMax attempts to apply the bulk charge voltage to the battery The system will switch to Bulk charge if the battery is sufficiently discharged and or insufficient charge current is available to drive the battery up to the bulk voltage set point During this stage the batteries are charged at the bulk voltage setting And the unit delivers as much charge current as possible to rapidly recharge the batteries When the battery voltage reaches the bulk voltage setting the charge controller activates the next stage absorption TrakMax will again switch to Bulk charge if battery voltage drops below the present charge voltage set point 4 2 2 2 Absorption Stage During this stage the u
12. KING MPPT Maximum Power Point Tracking frequently referred to as MPPT is an electronic system that operates the Photovoltaic PV modules in a manner that allows the PV modules to produce all the power they are capable of producing MPPT and associated current boost operation is fully automatic and will function whenever sufficient PV voltage and current are available The percent increase in output charge current relative to PV current is variable and will change with operating conditions When conditions are such that insufficient PV power is available to produce an increase in output current the unit will stop its internal DC DC power conversion and operate as a series pass PWM controller with very low forward voltage drop The principal operating conditions which affect current boost performance are PV array temperature and battery voltage At constant solar intensity available PV power changes with PV temperature A PV array s power vs temperature characteristic is such that a cool PV array can produce a higher voltage and more EES Page 12 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 power than a hot PV array When PV voltage is sufficiently high for MPPT to operate a constant power output is delivered to the battery Since output power is constant while MPPT is operating a decrease in battery voltage produces corresponding increase in charge current This means that the greatest current increase occurs with
13. TrakMax 40 User Manual Revision 1 0 windynation winodyunation cleon power to the people rakMax 4 MPPT charge controller LOAD BATTERY PV IrakMax 40 MPPT Solar Charge Controller CHC TRMX 40 User s Manual E Page 1 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 Table of Contents Nutte Le 3 1 1 LITE WY Ee Un EE 3 1 2 Ke 3 1 3 Warranty Claims amp Return Procedures 0c0 jascsieian EETeES AER ieee en Rivet ieee eee 3 1 4 Nie UE A 1 5 Limitation of Liability EE 4 2 Wel e 2 1 Features nn 2 2 Specifications 2 2 1 Electrical Specifications cece cceenesceeesneneeecesteeneneenensenenees 5 2 2 2 Physical Specifications EREI een n o n OEE eaten ene neee ea aeeeneeeneeeeeneeenee 6 2 2 3 Regulatory Imfoietionirr eeccesecceceeesseseceeseceteeeeeseee cee eteceee cesses eee neee naan eneeeeeeeeeneee nee 6 3 Installaton nn A ee ee 7 3 1 Electrostatic ESD PreCautions ANERE en eae ne aeae AEE nanen eaerenenerenerenerenene 7 3 2 Mounting aaa ee ge Bn OE aaaeeeaa 7 3 3 Grouf D A P E Runn M aaaea 8 3 4 Oe Ce ee ee ee ee 8 3 5 Oy retrrent Protection 8 8 S 2238 Ie Runnen EE en 10 3 6 Overvoltage Reverse Polarity Protection 10 3 7 FAIZ RCC ieee ee A ee ee ee 10 3 8 Communication Pet 28 eg nun fe Ech EEN eee 11 3 8 1 RC CO 2 BR A ee Ae ee ae 11 3 9 Battery Temperature Sensor BIS secceeseceesceeestetesceeesceceeeeestBaeseee
14. Y TYPE SELECTOR switch to position 0 or 1 a E Page 14 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 5 Reset the BATTERY TYPE SELECTOR potentiometer to the appropriate setting for the system batteries when the Equalize charge has completed 4 3 DC LOAD CONTROL The TrakMax can operate as a PV charge controller and can regulate up to 40 Amps of continuous photovoltaic PV array current at 12 24 volts DC for charging batteries At the same time the TrakMax can provide a maximum of 15 Amps of current to a DC load but the 40 Amp current rating is shared between the battery and the DC load The TrakMax uses voltage set points to determine when to disconnect or reconnect loads depending on battery voltage TrakMax prevents damage to the battery from over discharge during periods of poor weather or excessive loads and can charge the batteries in this function Dump Load Dump Load the si PV Array gt Ei 4 3 1 Auto Night Disconnect When using PV Charge Control mode the PV array is automatically disconnected from the battery at night to prevent reverse leakage of power and to protect the PV array 4 3 2 Low Voltage Disconnect When configured as a load controller the TrakMax will disconnect the load from the batteries when it reaches the low voltage disconnect LVD setting There will be a 1 minute delay after the voltage drops below the LVD setting before the controller
15. actually disconnects the load 4 3 3 Low Voltage Reconnect The TrakMax will also provide automatic reconnection of the loads at the low voltage reconnect LVR setting Reconnection of the load is allowed once the battery voltage has exceeded the low voltage reconnect LVR setting Loads are automatically reconnected when battery voltage exceeds the low voltage reconnect LVR setting for 1 minute Important When using the TrakMax in load control do not install the BTS Battery Temperature Sensor 4 4 BATTERY SELECTION It is important to select the battery type that matches the system battery to ensure proper charging and long battery life The battery type selector Figure 4 4 is a 10 position rotary switch used to set the TrakMax for the proper float and bulk voltage levels These levels are selected depending on the type of batteries used Refer to the table below for the charge voltages in the various switch positions Refer to the specifications provided by the battery manufacturer and choose a setting that best fits the recommended charging profile Jo art BATTERY SELECT Figure 4 4 Battery Type Selector 4 4 1 Battery Type Selector Switch Settings e Battery Type The common battery type associated with the specified charging settings e Float Stage When the battery is fully charged the charging voltage will be reduced to the Float voltage setting Page 15 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision
16. arge controller PV Array 4 Double Check All Connections to ensure they are secure 5 Replace the Wiring Cover removed in step 1 and secure with the two screws 6 Tighten the cable clamps if applicable CAUTION Risk of Fire and Shock Connect battery terminals prior to the connection of array terminals Page 9 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 3 5 OVERCURRENT PROTECTION Circuit breakers or fuses must be installed in both the battery and solar circuits The protection device ratings and installation methods must conform to NEC requirements The battery circuit fuses or circuit breaker must be rated to 125 of the maximum current or more The minimum fuse breaker rating allowed for use with each TrakMax is 1 25 x 40 Amps 50 Amps If the TrakMax controller system detects an overload status it will automatically reset the over current protection system every 6 minutes If the fault is still present the controller will shut off and wait for another 6 minutes This will occur continuously until the problem is corrected A disconnect is required for the battery and solar circuits to provide a means for removing power from the TrakMax Double pole switches or breakers are convenient for disconnecting both solar and battery conductors simultaneously 3 6 OVERVOLTAGE REVERSE POLARITY PROTECTION TrakMax is fully protected against reverse polarity and high voltage transients for both the PV and
17. at least 6 in 150 mm of clearance above and below and at least 1 in 25 mm on each side for proper air flow as shown in figure 3 1 below Figure 3 1 Required mounting clearance for airflow Place a mark on the mounting surface at the top of each keyhole two per unit Remove the controller and drill a 3 32 in 2 5 mm hole at the drill mark Insert a 10 screw into the pilot holes Do not tighten the screw completely Leave a 1 4 in 6 mm gap between the mounting surface and screw head Carefully align the keyholes on the TrakMax with the screw heads and slide the TrakMax down over the keyhole Tighten the keyhole screws Add two additional screws in the lower rectangular mounting cutouts DIPYN On Warning Explosion Corrosion Hazard Do not mount on flammable surface material e g wooden wall eS SS a a a Page 7 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 3 3 GROUNDING The TrakMax is designed to work with grounded electrical systems In the controller ground is not connected to the input terminal and output terminals Use a copper wire to connect the grounding terminal on the TrakMax enclosure to earth ground The grounding terminal is located on the lower right corner of the enclosure Do not connect the system negative conductor to this terminal NEC requires the use of an external ground fault protection device GFPD The system electrical negative should be bonded through a GFPD to eart
18. atification 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 indicates an imbalance exists If the battery construction prevents measurement of the individual cell voltages use a hydrometer A variation of 0 020 in the specific gravity between cells is considered significant Both conditions can be corrected by an equalization charge A proper equalization charge will not damage a vented liquid electrolyte type battery It may however cause significant electrolyte usage and require that the battery be refilled with distilled water to the correct level This may be a problem with unattended systems in remote areas which do not receive regular maintenance Consult the battery manufacturer for their recommendations 7 3 1 Equalization Set Points Non Sealed Batteries Only Battery Type Bulk Volts Float Volts Equalizing Charge Default Settings 14 0 VDC 13 5 VDC Disabled Sealed Gel Lead Acid 14 1 VDC 13 6 VDC Not recommended Consult battery manufacturer AGM Lead Acid 14 4 VDC 13 4 VDC Charge to 15 5 VDC or per manufacturer Maintenance Free RV Marine Deep Cycle Liquid Electrolyte Lead Antimony 14 6 VDC 13 4 VDC Charge to 15 5 VDC or per manufacturer NiCad or NiFe Alkaline 16 0 VDC 14 5 VDC _ Not recommended Consult battery manufacturer 14 4 VDC 1
19. ation or exclusion of implied warranties or how long an implied warranty may last so the above limitations may not apply to you In any such jurisdiction the warranty shall be limited to the minimum warranty and period required by law WINDY NATION EXPRESSLY DISCLAIMS ALL LIABILITY FOR BODILY INJURIES OR DEATH THAT MAY OCCUR DIRECTLY OR INDIRECTLY BY USE OF THE PRODUCT BY ANY PERSON 1 5 LIMITATION OF LIABILITY UNDER NO CIRCUMSTANCES WILL WINDY NATION OR ITS AFFILIATES OR SUPPLIERS BE LIABLE OR RESPONSIBLE FOR ANY LOSS OF USE INTERRUPTION OF BUSINESS LOST PROFITS LOST DATA OR INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND REGARDLESS OF THE FORM OF ACTION WHETHER IN GONTRACT TORT INCLUDING NEGLIGENCE STRICT LIABILITY OR OTHERWISE EVEN IF WINDY NATION OR ITS AFFILIATE OR SUPPLIER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE Some states do not allow the exclusion or limitation of incidental or consequential damages so these limitations may not apply to you Neither Windy Nation nor its affiliates or suppliers will be held liable or responsible for any damage or loss to any items or products connected to powered by or otherwise attached to the Product The total cumulative liability to Customer from all causes of action and all theories of liability will be limited to and will not exceed the purchase price of the Product paid by Customer This warranty gives the Customer specific legal rights and the Custome
20. eO SNC BB Z ee oe WA e Raae 18 5 2 4 Over GUient of Load Se eg Mm OR cere MRM ee 18 6 Troubleshooting ANG Support Assen EEREEREEEEREE e eonenna renere 18 6 1 Oe rt e T EE 18 6 2 Troubleshootng ffe aoe eeeceeeeeceeeeeseeeeeeeeeeeeeseneeeeesceeeeteseeeeerees ee oa eeeccieeeeceeeeeeseceeeeeseeeesseeeeees 18 6 3 feel ee he lle 19 7 Batteries eee eee Eegenen eee eeseeeeneceeceenseeseneeseeeeneseeseenes 19 7 4 Battery Types eene EERSTEN 19 TAAL Automotive EE 19 7 1 2 Maintenance Free Batteries cccecceeceseeeeeseeceeeeeeceeenseeee eg enseenneeseeeageesenesceenseeneessseeeesenenseseseeeeesnsenens 19 lee iDeep Cycle Batteries aneron nean ea E EEEa ES deeded ect A E a EA ee pelea 19 TAGE Sealed RE 20 7 2 EE Le ET 20 7 3 Equalization Charging WEE 20 7 3 1 Equalization Set Points Non Sealed Batteries Oniy 20 EE Page 2 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 1 INTRODUCTION Windy Nation Inc Windy Nation is not assembling the wind unit installing the solar system or any other product offered by Windy Nation Windy Nation and its directors officers and employees disclaim and by purchasing a Windy Nation wind or solar powered product you accept all liability and responsibility for damage to property injury or death arising out of or related to the use or misuse of any product offered by Windy Nation 1 1 LIMITED WARRANTY Windy Nation warrants that the MPPT Charge Contr
21. eries the longer the system can operate before recharging is necessary An undersized battery bank results in short 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 7 3 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 If the sulfate remains on the plates for an extended period of time it will harden and seal off a percentage of the plate area reducing the capacity of the battery By equalizing the batteries before the sulfate hardens the sulfate is removed from the plates Batteries with liquid electrolyte may become stratified Stratification concentrates the sulfuric acid into the bottom of the cell while the top becomes diluted This corrodes the lower portion of the plates reducing battery life Mixing of the electrolyte by the formation of gas bubbles during the equalization process reduces str
22. ery temperature sensor included is built for long term reliability The sensor element is environmentally sealed and encapsulated into a lug which adheres directly to the battery The TrakMax also includes an isolated RJ11 port for connection to a PC computer for data logging and system monitoring For large system current applications greater than 40 amps multiple TrakMax units can be connected in parallel 2 1 FEATURES DC Load Output Port Optional battery temperature sensor ensures precise battery charging LED displays to indicate the status of charge Lightning protection Reverse current protection at night Three stage battery charging bulk absorption and float with optional temperature compensation Automatic overload protection in both active and passive modes Microprocessor controlled Silent pulse width modulated PWM high efficiency operation Auto detects system voltage 12 or 24 volt at start up 2 2 SPECIFICATIONS 2 2 1 Electrical Specifications Parameter Value 25 C Battery System Voltage gern SANA 3 12 24 VDC 1 9 18VDC battery voltage TrakMax auto detects 12 volt battery system 2 18 36VDC battery voltage TrakMax auto detects 24 volt battery system Max Battery Charging Current 40 Amp Load Current 15 Amp Photovoltaic Input Voltage Range 12 55VDC 12 30VDC 12 volt battery charging 30 55VDC 24 volt battery charging Max PV Open Circuit Array 55VDC Voltage Efficiency 97 min full cu
23. eseeesaeesadeeecaceseaeeceeeeeaeteseeseseeenaaentaeeees 11 3 9 1 Temperature Compsnsatigh 0 Taan SRE D A E OE N R 11 3 9 2 Wiring the Battery Temperature Sensor BIG 12 4 peration g Mim 296 P RK be eee eee eee ee ee d A a 12 4 1 Maximum Power Point Tracking MPPT EEN 12 EIN 1 O A TC EEEE TEE eee ee Sere 13 4 2 Charge Magiessz A E WR 8 RS A A 13 42 1 factory Default Settiggs Ma S SA BR sc un DEER 13 42 2 hree Stage Cnarge B B ce f Bees BP A Sm Be Beef eee en 14 o FRR EE Cece ee EE ee eee A 14 4 3 Ee Betle MCs siico eer eee ees Secret see D 15 Mot Auto Night Disconnect S cesesccneesececeeeseeeeeneneeenneeneeeeneeeeeeeeeeeenegfMeeseeseeeeeeeeneeresere essere n i 15 Zeep Lg Voltage LDisconpec h SAS Ka MOD A etree eee eeeere epee ee ees N 15 4355 Low Voltage Recommiect A he bite E gee cece Mee ee Be MR eee eee Meee ee N 15 4 4 Batter Selection 98 See Are D Seer oe 15 4 4 1 Battery Type Selector Switch Settings ceecceceseeseeeennaaileeceseeesseeeesceeeeeeeeeddbaeeesseeeseeepeeeecseeesnanenseeeenaees 15 Ce SD CeCe ne ee Aan 16 5 1 large C htrol fN a A EE 17 5 2 LIED ele 5 SZ A8 Ee mr EE D 2998 ee R 17 5 2 1 Low Voltage Disconnect LVD 2 a T aaa AE aaaea 18 5 2 2 OWeNoltage ON oad m domed Sir a WW Sg MO eee cece nate neta 18 C
24. h ground at one and only one location The grounding point may be located in the solar circuit or the battery circuit 3 4 CONNECTIONS WARNING Shock Hazard Solar PV array can produce open circuit voltages in excess of 100 VDC when in sunlight Verify that the solar input breaker or disconnect has been opened disconnected before installing the system wires Note that the maximum PV open circuit voltage for the TrakMax is 55 VDC Do NOT attach the positive and negative PV cables to the TrakMax until the TrakMax has been connected to the positive and negative terminals of the 12 or 24 volt battery bank It is recommended to use a Strain relief bushings connectors clamp connectors or wire glands in each of the three 1 2 in openings The NEC requires that the wires carrying the system current never exceed 80 of the conductor s current rating The table below provides the minimum size of copper wire allowed by NEC Wire types rated for 75 C and 90 C are included Wire Type 75 C Wire 90 C Wire Copper 6 AWG 16 mm 8 AWG 10 mm Aluminum 4 AWG 25 mm _ 6 AWG 16 mm 1 Remove the Wiring Cover from the Top Cover by removing the two securing screws as shown below windunation Remove two 2 Cover Screws 2 Route the relevant cable wire through the appropriate Le in opening as noted on the cover Note If strain reliefs i e cable clamps wire glands are being used they must be installed pri
25. high temperature environments If excessive temperatures are detected while operating in charge mode the controller will decrease the charge current to reduce the transistor temperature and the green led will be solid green If the TrakMax is connected with a DC load the load is disconnected before the transistors reach an excessive temperature and the green LED flashes Once the temperature has dropped the loads are reconnected 5 2 4 Over Current of Load If the controller detects an overload or short circuit on the load it will automatically reset the over current protection system every 6 minutes If the default is still present the controller will shut off and wait another 6 minutes This will occur continuously until the problem is corrected 6 TROUBLESHOOTING AND SUPPORT The TrakMax is ruggedly constructed and requires minimal care It is recommended to inspect all the controller connections two times per year for insulation damage or corrosion and to ensure all connections are tight and secure CAUTION Shock Hazard Disconnect all power sources to the controller before removing the wiring box cover Never remove the cover when voltage exists on the power connections 6 1 CARE Clean the heat sink and area around the controller of any dirt or debris with a moistened cloth Inspect the battery bank for cracked or bulging cases and corroded terminals For wet Cell flooded batteries make sure the water level is maintained according to the
26. ill increase or decrease the battery charging voltage depending on the temperature of the battery to optimize the charge to the battery and to maintain battery performance 2 2 2 Physical Specifications Parameter Value Dimension H x W x D 7 56 192mm x 5 51 140mm x 2 6 66mm Unit Weight 3 1 Ib 1 4Kg Mounting Vertical wall mount indoor only Cooling Natural cooling Operating Temperature 0 C to 40 C 40 C to 60 C de rating Storage Temperature 25 C to 70 C Operating Humidity 20 to 80 relative humidity non condensing Non Operating Humidity Greater than 95 relative humidity 38 7 C max wet bulb temperature with no damage 2 2 3 Regulatory Information The TrakMax has safety approvals as follows e UL1741 FCC Part 15B EN61000 6 3 2001 EN61000 6 1 2001 EN 60335 1 FCC Requirements This device complies with Part 15 of the FCC rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation E Page 6 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 3 INSTALLATION Insure all terminating connections are clean and tight to prevent arcing and overheating Do not connect to a PV array capable of producing greater than 40 amps of short circuit current 25 C Do not connect to a PV array with an open circuit voltage
27. ill provides approximately the same current But because output voltage is now at 12 volts rather than 17 volts the PV module s power production is artificially limited and the 75W PV module only delivers 53 watts This wastes 22 watts of available power TrakMax s MPPT technology operates in a very different fashion Under these conditions TrakMax calculates the maximum power voltage V at which the PV module delivers maximum power in this case 17 volts It then operates the PV module at 17 volts which extracts maximum available power from the PV module TrakMax continually recalculates the maximum power voltage as operating conditions change Input power from the maximum power tracking controller in this case 75 watts feeds a switching type power converter which reduces the 17 volt input to battery voltage at the output The full 75 watts which is now being delivered at 12 volts would produce a current of 6 25 amps A charge current increase of 1 8 amps or 40 is achieved by converting the 22 watts that would have been wasted into useable charge current Note that this example assumes 100 efficiency to illustrate the principal of operation In actual operation the power boost will be somewhat less 4 2 CHARGE MODE 4 2 1 Factory Default Settings Charge Mode Three 3 Stage Absorption Voltage 14 4V 28 8V Bulk Voltage 14 6V 29 2V Float Voltage 13 4V 26 8V Equalize 14V 28V aaa Page 13 of 20 windynation 03 0
28. nit changes to a constant voltage mode where the absorption voltage is applied to the battery When charge current decreases to the float transition current setting the battery is fully charged and the unit switches to the float stage 4 2 2 3 Float Stage During this stage the float voltage is applied to the battery to maintain it in a fully charged state When battery voltage drops below the float setting for a cumulative period a new bulk cycle will be triggered 4 2 3 Equalization Equalize charging is a special mode of battery charging During use the battery s cells can become unequal in the voltage and current they can deliver This is due to a buildup of sulfate on the plates as well as stratified electrolyte Sulfate prevents the cells from receiving or delivering full power If the sulfate is left on the plates it will harden and permanently reduce the battery s capacity Stratification separates the heavier acid from the water and the concentrated acid remains at the lower portion of the plates eventually corroding them Equalizing the batteries every month or two depending on usage prolongs the life of the batteries and provides better battery performance To set the Equalize Charge 1 Remove all DC loads connected to the batteries 2 Remove all battery vent caps 3 Check the battery water level it should be just over the top of the plates do not over fill Use only distilled water for filling batteries 4 Set the BATTER
29. oller the Producer will be free from manufacturing defects in materials and workmanship under normal authorized use consistent with product instructions for a period of one 1 year from the date the original purchaser Customer receives the Product the Warranty Period This warranty extends only to the original purchaser The Customer s sole and exclusive remedy and the entire liability of Windy Nation its suppliers and affiliates for breach of the warranty is at Windy Nation s option either i to replace the Product or defective component part s with a new or reconditioned Product or component part s ii to repair the reported problem or iii to refund the purchase price of the Product Repaired or replaced products are warranted for the remainder of the original warranty period only No employee agent dealer or other person is authorized to give any warranties on behalf of Windy Nation not expressly set forth in this limited warranty 1 2 RESTRICTIONS No warranty will apply if the Product i has been altered or modified except by Windy Nation ii has not been installed operated repaired or maintained in accordance with instructions supplied by Windy Nation iii has been subjected to abnormal physical thermal or electrical stress misuse negligence or accident If Windy Nation determines that the problem with the Product isnot due to a manufacturing defect in Windy Nation s workmanship or materials or
30. or to routing the wire and the wire should route through the clamp LOAD BATTERY ee Page 8 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 3 Terminal connectors for DC wiring are located on the lower edge of the circuit board Once the wires have been installed tighten the terminals with the screw located on the top of the terminals to 1 2Nm 10 6lb in Be careful not to over tighten Tighten Terminals Here Insert Wire Cable Here a Load Maximum 15A DC Load e Connect a cable from the TrakMax terminal marked load negative to the negative terminal of your DC load and tighten the screw e Connect a cable from the TrakMax terminal marked load positive to the positive terminal of your DC load and tighten the screw b Battery 40A Rated Charge Current e Connect a cable from the TrakMax terminal marked battery negative to the negative battery terminal and tighten the screw e Connect a cable from the TrakMax terminal marked battery positive on the Solar charge controller to the positive battery terminal and tighten the screw c PV Photovoltaic System e Connect the PV array s positive output to the terminal marked PV positive on the TrakMax and tighten the screw e Connect the PV array s negative output to the terminal marked PV negative on the TrakMax and tighten the screw windynation power to the people TrakMax MPPT ch
31. otherwise does not qualify for warranty repair then the Customer will be responsible for the costs of all necessary repairs and expenses incurred by Windy Nation 1 3 WARRANTY CLAIMS amp RETURN PROCEDURES To be eligible for service under this warranty the Customer must submit a service request within the Warranty Period by contacting Windy Nation in writing or via telephone and obtaining a Returned Materials Authorization RMA number This RMA must be obtained before returning any product under this warranty Notification must include a description of the alleged defect the manner in which the Product was used the serial number and the original purchase date in addition to the name address and telephone number of the Customer Within five 5 business days of the date of notification Windy Nation will provide the Customer with an RMA number and the location to which the Customer must return the defective Product Any Product returned for warranty service shall be shipped at the expense and risk of the Customer The Customer must return the entire Product kit or if authorized by Windy Nation the defective component parts within fifteen 15 days after issuance of the RMA number Windy Nation will be under no obligation to accept any returned Product that does not have a valid RMA number Customer s failure to return the Product within fifteen 15 days of its receipt of an RMA number may result in cancellation of the RMA All parts tha
32. r and inexpensive deep cycle battery is the golf cart battery It is a 6 volt design typically rated at 220amp hours RV and marine deep cycle batteries are also popular for small systems They are usually referred to as Group 24 or Group 27 a ee ee ee Page 19 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 batteries and are rated at 80 to 100 amp hours at 12volts Many larger systems use L16 batteries which are usually rated at 350amp hours at 6 volts each They are 17 inches high and weigh about 130pounds 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 7 1 4 Sealed Batteries Another type of battery construction is the sealed gel cell They do not use battery caps The electrolyte is in the form of a gel rather than a liquid which allows the batteries to be mounted in any position The advantages are no maintenance long life 800 cycles claimed and low self discharge Absorbed glass mat AGM electrolyte batteries are also acceptable Their electrolyte is contained in mats between the battery plates Sealed batteries reduce the maintenance requirements for the system and are good for remote applications They are much more sensitive to the charging process and can be ruined in as little as a day of overcharging 7 2 BATTERY SIZING Batteries are the fuel tank of the system The larger the batt
33. r may also have other legal rights that vary from state to state a oe SS Seal Page 4 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 2 PRODUCT OVERVIEW The TrakMax solar charge controller is a 40 amp 12 24 Volt Maximum Power Point Tracking MPPT photovoltaic PV battery charge controller Through the use of MPPT technology TrakMax can increase charge current up to 30 or more compared to conventional solar charge controllers TrakMax s sophisticated three stage charge control system can be configured to optimize charge parameters to precise battery requirements The unit is fully protected against voltage transients over temperature over current reverse battery and reverse PV connections An automatic current limit feature allows use of the full 40 amp capability without worrying about overload or unnecessary fuse blows from excessive current voltage or amp hour based load control Series pass Pulse Width Modulation PWM charge voltage control combined with a multistage charge control algorithm leads to superior charging and enhanced battery performance The filtered PWM power control system uses highly efficient and reliable power MOSFET transistors The MOSFET s are turned on and off at high frequency to precisely control the charge voltage and the MPPT function Fully automatic temperature compensation of charge voltage is available to further improve charge control and battery performance The optional batt
34. rrent Typical Idle Consumption At idle lt 10mA EES Page 5 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 Overload Protection DC load 2 0 Inom gt 5s 1 5 Inom gt 20s 1 25 Inom temperature controlled Bulk Charge adjustable 14 6V default 29 2V default Floating Charge adjustable 13 4V default 26 8V default Equalization Charge 14 0V default 28 0V default Overcharge Disconnection 14 8V 29 6V Overcharge Recovery 13 6V 27 2V Over discharge Disconnection 10 8 V default 21 6V default Over discharge Reconnection 12 3V 24 6V Temperature Compensation 13 2mV C 26 4mV C Lead Acid Battery Settings Adjustable NiCad Battery Settings Adjustable Load Control Mode 1 Low Voltage Reconnect LVR 2 Low Voltage Disconnect LVD Auto disconnect Low Voltage Reconnect 12 0 14 0 VDC 24 0 28 0 VDC Low Voltage Disconnect 10 5 12 5 VDC 21 0 25 0 VDC Ambient Temperature 0 40 C full load 40 60 C de rating Altitude Operating 5000 m Non Operating 16000 m Enclosure Protection Class IP21 Battery Temperature Sensor Optional remote sensor increases charging precision BTS Terminal Size fine single wire Maximum 6 AWG NOTE The optional battery temperature sensor automatically adjusts the charging process of the controller according to the type of battery selected by the user With the battery temperature sensor installed the controller w
35. t Windy Nation replaces shall become Windy Nation s property on the date Windy Nation ships the repaired Product or part back to the Customer Windy Nation will use all reasonable efforts within thirty 30 days of receipt of the a SSS E Page 3 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 defective Product to repair or replace such Product If a warranty claim is invalid for any reason the Customer will be charged at Windy Nation s then current rates for services performed and will be charged for all necessary repairs and expense incurred by Windy Nation If Windy Nation determines that a warranty claim is valid it will ship the repaired or replaced Product to Customer at Windy Nation s cost 1 4 DISCLAIMER EXCEPT FOR THE EXPRESS LIMITED WARRANTY SET FORTH IN THE PREVIOUS PARAGRAPH WINDY NATION DISCLAIMS ALL WARRANTIES EXPRESS IMPLIED AND STATUTORY INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ANY PRODUCTS PROVIDED BY WINDY NATION NO ORAL OR WRITTEN INFORMATION OR ADVICE GIVEN BY WINDY NATION ITS DEALERS DISTRIBUTORS AGENTS OR EMPLOYEES SHALL IN ANY WAY INCREASE THE SCOPE OF THIS WARRANTY WINDY NATION DOES NOT WARRANT THAT THE QUALITY OR PERFORMANCE OF THE PRODUCTS WILL MEET YOUR REQUIREMENTS OR THAT YOU WILL BE ABLE TO ACHIEVE ANY PARTICULAR RESULTS FROM USE OR MODIFICATION OF THE PRODUCTS Some jurisdictions do not allow the limit
36. the battery connections If the battery is connected in the reverse polarity position the TrakMax inner fuse will open If the PV array is connected in the reverse polarity position the TrakMax will not turn on System Voltage PV Over Voltage Point 12V Battery 30VDC 24V Battery 55VDC 3 7 PARALLEL CONNECTION Multiple TrakMax controllers can be installed in parallel on the same battery bank to achieve higher charging current For example connecting two TrakMax units in parallel can allow for 80 amps of charging current and connecting three TrakMax units in parallel can allow for up to 120 amps of charging current Additional parallel controllers can also be added in the future Each TrakMax MPPT Controller must have its own PV array See figure 3 5 windynation windunation power te the poopie power to the people TrakMax PPT charge controller MPPT charge TrakMax 40 PV Array PV Array LE T d Battery Figure 3 5 Parallel Connection Page 10 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 3 8 COMMUNICATION PORT Network connections allow the TrakMax to communicate with other controllers or computers 3 8 1 Remote RJ11 Use standard 4 wire or 6 wire RJ 11 telephone cables straight through not a Null Modem cross over If possible pull the telephone cable through conduit before crimping on the RJ 11 connectors If using pre assembled cables
37. v cell for lead acid type batteries and 2mv cell for alkaline type batteries NiCad or NiFe The temperature compensation calculations are derived from the following table E RR Page 11 of 20 windynation 03 06 2013 TrakMax 40 User Manual Revision 1 0 Battery Type 12 Volt Units 24 Volt Units Lead Acid 0 03 volts 30mv per degree Celsius 0 06 volts 60mv per degree Celsius 0 02 volts 20mv per degree Celsius 0 04 volts 40mv per degree Celsius 3 9 2 Wiring the Battery Temperature Sensor BTS 1 Plug the provided RJ11 cable into the RJ11 socket labeled BTS located on the side of the TrakMax as shown below caution al Install in dry protected g 555 location WA REMOTE BTS Disconnect PV array prior to any connections or maimienance 2 Secure the BTS on the side of the battery below the electrolyte level as shown below 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 To BTS Port CAUTION High power electrical systems pose dangers and it is the user s responsibility to be familiar with these dangers and take any necessary action to ensure safe use Shorting a battery or connecting your controller to a battery can supply huge currents and have serious consequences including explosions causing fire damage to equipment and personal injury 4 OPERATION 4 1 MAXIMUM POWER POINT TRAC
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