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Xantrex Technology C35 Power Supply User Manual

1. 38 DC Terminal Connector Locations 38 Terminal Torque Requirements 39 Wire Size and Over current Protection Requirements 39 Current Rating 39 Minimum Recommended Wire Gauge 40 Surge Protection 40 Over current Protection 41 Long distance wire runs 42 Maximum One way Distance and Wire Size 42 PV Charge Control Mode Wiring 44 Diversion Control Mode Wiring 46 DC Load Control Mode Wiring 48 Installing Optional Accessories 50 Installing a Digital Display 50 Installing the Battery Temperature Sensor 51 Reinstalling the Faceplate 52 975 0004 01 02 Rev D Contents 3 Operation Basic Operation 54 LED Status Indicator 55 Charge Control or Diversion Control Indications Green 56 Blinking Green 57 Solid Green 57 Equalization Mode Indication Red green 58 Load Control Indications Red 58 Blinking Red
2. 14 Removing the Top Cover 14 Removing Knockouts 14 Mounting the Controller 16 Configuring the C Series Controller 18 Jumper Settings 18 Operating Mode Jumper 20 Voltage Jumper 20 xi Contents xii Automatic Manual Battery Equalization EQ and Low Voltage Reconnect LVR Jumper 21 Adjusting the C Series Voltage Settings 22 Setting Voltage Parameters for Charge Control Mode 22 Setting Voltage Parameters for Load Control Mode 24 Setting Voltage Parameters Diversion Control Mode 26 Setting Voltage Parameters for Alkaline Batteries 26 Using a Digital Voltmeter to Adjust Voltage Settings 28 Equalization Charging 30 Manual Equalization 31 Automatic Equalization 32 Terminating the Equalization Process 33 Temperature Compensation 33 Temperature Compensation Based on Battery Type 34 Automatic Battery Temperature Compensation 34 Manual Battery Temperature Compensation 36 Grounding 37 Wiring
3. 20 Voltage Selection Jumper 20 EQ LVR Jumper and Reset Switch 21 Bulk and Float Charge Potentiometers pots 22 Bulk and Float Charge Settings for Charge Diversion Control Mode 23 Potentiometers with Decal for LVR and LVD Settings 24 LVR and LVD Settings for Load Control Mode 25 R46 Resistor Location 26 Voltage Settings with R46 Resistor Clipped 27 Test Points for Adjusting Voltage Using a DVM 29 Manual Equalization Settings 30 Front Panel LED and Reset Switch Location 31 Auto Equalization Settings 32 Terminating the Equalization Charge 33 Grounding the C Series Chassis 37 DC Connection Terminals 39 XV 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 40 PV Charge Control Mode Wiring 45 Diversion Control Mode Wiring 47 Load Control Mode Wiring 49 Installing a Digital Display 50 Installing the BTS 51 Re installing the CM Faceplate 52 C Series Status LED and Rese
4. 58 Solid Red 58 Error Mode Indication Orange 59 Over temperature Condition 59 Over Current Condition 59 Low voltage Disconnect Condition 60 Reconnecting to Loads 60 Reset Switch 61 4 Troubleshooting PV Charge Control Troubleshooting 64 Diversion Control Troubleshooting 66 Load Control Troubleshooting 68 A Specifications Electrical Specifications 70 Features and Options Specifications 71 Environmental Specifications 72 B Batteries Battery Types 74 Automotive Batteries 74 Maintenance Free Batteries 74 Deep Cycle Batteries 74 Sealed Batteries 75 NiCad and NiFe Batteries 76 975 0004 01 02 Rev D xiii Contents Battery Sizing 76 Equalization Charging 77 Equalization Setpoints Non Sealed Batteries Only 79 C Diversion Loads Diversion Load Types 82 Warranty and
5. Float 14 5 16 5 Vdc Bulk 15 0 17 0 Vdc EQ not recommended Float 29 0 33 0 Vdc Bulk 30 0 34 0 Vdc EQ not recommended Float 58 0 66 0 Vdc Bulk 60 0 68 0 Vdc EQ not recommended 975 0004 01 02 Rev D 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 LVR 12 0 to 14 0 Vdc LVD 10 5 to 12 5 Vdc 24 Volt System 48 Volt System LVR 24 0 to 28 0 Vdc LVR 48 0 to 56 0 Vdc LVD 21 0 to 25 0 Vdc LYD 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 Table A 2 Features and Options Specifications Model C35 c40 c60 Standard Features Status Indicator Multi color LED indicates the operating battery voltage status Low Voltage Disconnect Load Control Mode User selectable manual or automatic reconnection includes warning flash before disconnect and 6 minutes grace period Equalization Charge Charge Control Mode User selectable manual or automatic equalization every 30 days Short Circuit Protection Fully electronically protected with auto reset Adjustable Control Two user adjustable voltage setpoints for control of loads or charging Setpoints test points sources
6. C Series Multifunction DC Controller C35 c40 c60 www xantrex com 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 Trademarks C Series Multifunction DC Controller is a trademark of Xantrex International Xantrex is a registered trademark of Xantrex International Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes only Notice of Copyright C Series Multifunction DC Controller Owner s Guide November 2003 Xantrex International All rights reserved Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY INC XANTREX a MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION b ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE WHETHER DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTA
7. Disconnect SHUNT amp NEGATIVE BUS DC DISCONNECT Ensure the proper grounding is in place for the entire system Figure 2 23 PV Charge Control Mode Wiring 975 0004 01 02 Rev D 45 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 3 Run a negative wire from the DC current source PV wind hydro etc to the battery negative terminal 4 Connect a cable from controller terminal marked BAT POS to the battery disconnect 5 Connect a cable from the battery disconnect to the positive terminal of the battery 6 Connect a cable from the negative battery terminal to one of the terminals marked COMMON NEGATIVES on the controller s circuit board 7 Connect a cable from the controller s other terminal marked COMMON NEGATIVES to the negative terminal of your DC diversion load 8 Connect a cable from the controller s terminal marked PV LOAD to the positive terminal of your DC diversion load 9 Tighten per torque requirements outlined on
8. 13 66 m 17 13 m 21 61m 34 41 m 25 5 6 ft 8 9 ft 14if 224f 283f 35 8f 45 0f 56 78 903 ft 1 71 m 2 71m 430m 83m 8 63m 10 91 m 13 72 m 17 28 m 27 52 m 30 4 7 ft 7 4 ft 11 8 ft 18 7f 23 6f 299f 37 5f 47 2ft 75 3 ft 1 43 m 2 26m 3 60m 5 70m 7 19m 9 11 m 11 43 m 14 39 m 22 95 m 35 6 4 ft 10 1 ft 16 0f 202f 256f 3218 405f 64 5 ft 1 95m 3 08m 488m 6 16m 7 80m 9 78m 12 34 m 19 66 m 40 5 6 ft 8 8 ft 14 0ft 177f 224f 28 1f 35 4ft 56 5 ft 71m 268m 4 27m 639m 683m 8 56m 10 79 m 17 22 m 45 7 8 ft 12 5ft 157f 199f 25 0f 31 5ft 50 2 ft 238m 8 81m 4 79m 6 07m 7 62m 9 60m 15 30 m 50 7 1 ft maw eor Miron osr Maarn Meon 216m 8 41m 4 33m 5 46m 6 86m 8 63 m 13 78 m 60 6 3 ft 9 3 ft gf 149 187f 23 68 37 6 ft 192m 283m 60m 4 54m 67m 7 19m 115m a These wire sizes are not approved by U performance 975 0004 01 02 Rev D L to be installed in the controller but may be used externally of the controller using a splicer block to reduce voltage drop and improve 43 Installation PV Charge Control Mode Wiring The procedure below is illustrated in Figure 2 23 44 WARNING Shock Hazard PV arrays generate voltage whenever light strikes the s
9. Installation Minimum Recommended Wire Gauge The minimum recommended wire gauge is e C35 and C40 Models 8 AWG with a 75 C 167 F insulation rating e 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 mm copper or aluminum wire However UL specifications only allow the use of up to 6 AWG 13 3 mm maximum No crimp on terminals or lugs are required Bn WHOS HO OE SC Size 14 12 10 8 6 4 3 2 Diameter 073 072 115 146 184 235 281 295 FLAL Size 1 1 0 2 0 3 0 4 0 Diameter 335 380 420 475 530 Figure 2 22 AWG Wire Gauge Reference Chart Important Figure 2 22 is for reference only Sizes shown are for the conductor Do not include any insulation when determining your wire size Due to printing anomalies these dimensions may not be to scale Surge Protection Since PV arrays are often mounted on an elevated structure and thus are more susceptible to lightning strikes protection from lightning induced power surges and other transient power disturbances between the PV array and the C Series 40 975 0004 01 02 Rev D 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 protecti
10. Positive Positive Negative Negative DC DISCONNECT NEGATIVE GROUND BOND guer BATTERY BANK 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 Important Ensure the voltage jumpers on the back of the CM or CM R match the system voltage as configured inside the controller unit See the C Series Meter Displays Installation Guide for additional information Digital Meter Display Port C Series Circuit Board Serial Communication Cable N i Figure 2 26 Installing a Digital Display 50 975 0004 01 02 Rev D 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 Po
11. and Canada CSA C22 2 No 107 1 95 2 year limited warranty Operating Modes The DC controller is a critical component in any solar wind or hydro power generation system and protects the batteries from over discharge and over charge conditions The C Series has two operating modes Charge Control mode and Load Control mode determined by the Operating mode jumper See Figure 2 5 These two different operating modes allow the C Series to be installed and function as three different DC controllers Charge Control Mode e PV Charge Controller controls charging in PV installations e Diversion Controller used in PV wind or hydro installations to divert any excess energy to a diversion load and in the case of a wind or hydro generator helps to prevent over spin damage Load Control Mode e Load Controller prevents damage to the battery from over discharge during periods of poor charging or excessive loads 975 0004 01 02 Rev D 3 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 When charging the C Series controlle
12. Al n e LVD LOAD 24 _LV D LOAD 11 5 i Low VoLtace 23 97 Low VOLTAGE 11 3 K DISCONNECT 22 6 a DISCONNECT 11 1 7T 22 2 T 10 9 10 7 10 5 21 8 94 4 21 0 12 Volt System Settings 24 Volt System Settings 54 4 sid 56 0 e a K L V R LOAD 52 0 2 Low VOLTAGE 512A J RECONNECT 504 ZTN 49 6 48 8 48 0 48 4492 50 0 aea l a Na L V D LOAD 46 0 Low VOLTAGE a d DISCONNECT 45 2 AS 44 4 TPN 43 6 408 42 0 48 Volt System Settings C40 only Figure 2 12 LVR and LVD Settings for Load Control Mode 975 0004 01 02 Rev D 25 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 After one hour at the BULK setting the unit will reduce the battery charging voltage to the FLOAT voltage setting This will usually result in more current being diverted to the diversion load Setting Voltage Parameters for Alkaline Batteries If using NiCad or NiFe batteries the required charging voltages may be higher than the designed settings of the C Series controller Charging voltages c
13. States and Canada How do you get service If your product requires troubleshooting or warranty service contact your merchant If you are unable to contact your merchant or the merchant is unable to provide service contact Xantrex directly at Telephone 1 800 670 0707 toll free North America 1 360 925 5097 direct Fax 1 800 994 7828 toll free North America 1 360 925 5143 direct Email customerservice xantrex com 85 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 What proof of purchase is required In any warranty claim dated proof of purchase must accompany the product and the product must not have been disassembled or modified without prior written authorization by Xantrex Proof of purchase may be in any one of the following forms The dated purchase receipt from the original purchase of the product at point of sale to the end user or The dated dealer invoice or purchase receipt showing original equipment manufacturer OEM status or The dated invoice or purchase receipt showing the product exchanged under warranty What does this warranty not cover This Limited Warranty does not cover normal wear and tear of t
14. be protected Check with the manufacturers of the DC equipment being powered for its maximum DC input voltage tolerance If equalization is expected to occur then the DC equipment being used must tolerate the voltages which will occur during the equalization process Battery Sizing Batteries are the fuel tank of the system The larger the batteries 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 76 975 0004 01 02 Rev D 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 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 t
15. circuit board above the reset switch to the appropriate AUTO pin set See Figure 2 18 Manual Equalize Default Setting l Auto Equalize i Figure 2 16 Manual Equalization Settings When automatic has been selected an equalization charge will occur every 30 days During the equalization process the status LED indicates equalization by alternately blinking green and red Important The auto equalization period is reset when DC power is removed from the controller 975 0004 01 02 Rev D 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 Front Panel LED flashes red green during equalization Reset Switch Access Figure 2 17 Front Panel LED and Reset Switch Location The equalization process will continue until the batteries have been held at or above the bulk setting for two hours of accumulated time Once the battery voltage has been at or above the bulk setting for a cumulative period of two hours the C Series will return to the float stage of the charging process During the equalization process the status LED will alternate between red and green and will not provide any other mode status indication Large battery banks may need several equalization cycles to fully stir the elect
16. of your dated proof of purchase Record these details in Information About Your System on page 89 975 0004 01 02 Rev D 87 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 e A return address where the unit can be shipped Post office boxes are not acceptable e A contact telephone number where you can be reached during work hours e A brief description of the problem 3 Ship the unit prepaid to the address provided by your Xantrex customer service representative If you are returning a product from outside of the USA or Canada In addition to the above you MUST include return freight funds and are fully responsible for all documents duties tariffs and deposits If you are returning a product to a Xantrex Authorized Service Center ASC A Xantrex return material authorization RMA number is not required However you must contact the ASC prior to returning the product or presenting the unit to verify any return procedures that may apply to that particular facility Out of Warranty Service If the warranty period for your C Series Mult
17. old batteries Contact your local recycling center for proper disposal information viii 975 0004 01 02 Rev D Battery Safety Information CAUTION A battery can produce the following hazards to personal safety e electrical shock e burn from high short circuit current and or e fire or explosion from vented gasses Observe proper precautions when working with or around batteries 975 0004 01 02 Rev D ix Contents Important Safety Instructions vii 1 Introduction Features 2 Operating Modes 3 Charge Control Mode 4 Three Stage Battery Charging 4 Battery Temperature Compensation 6 Manual or Auto Equalization Charge 6 Load Control Mode 6 Controller Functions 7 Photovoltaic Charge Controller 7 Automatic PV Array Night Disconnect 8 Diversion Controller 8 Diversion Loads 9 Load Controller 10 Low Voltage Disconnect 11 Low Voltage Reconnect 11 Optional Accessories 12 2 Installation Pre Installation
18. or 24 volts C60 or C35 models or 12 24 or 48 volts DC C40 model for charging batteries This rating includes the NEC required derating AANA eseese sse e a co e n e a 2 e008 ST E gt ry TI J e aAa 8 lt r P EL Ga Aoro 3 C Series E Mutttunction j DC Controller PV Array a ka cece esos cooo aaoo t Figure 1 3 PV Charge Controller If the PV array s output increases above the rated amp level due to reflection or edge of cloud effect the controller will continue to operate until the heatsink reaches a maximum safe operating temperature This will take several minutes to occur depending upon the ambient temperature involved When the heatsink reaches the maximum safe temperature the controller will reduce the current cooling the transistors and the heatsink 975 0004 01 02 Rev D 7 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 Automatic PV Array 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 This eliminates the need for a blocking diode between the battery and the
19. page 39 Allow a little slack on the cables within the controller and secure the wiring with strain reliefs Important Do not use light bulbs for diversion loads Use only resistive loads such as air or water cooled heating elements 46 975 0004 01 02 Rev D Wiring Common Negatives Battery Diversion Load Battery Diversion Load Positive Positive Negative Negative A Ensure the proper grounding is in ii aaa place for the entire system Figure 2 24 Diversion Control Mode Wiring 975 0004 01 02 Rev D 47 Installation DC Load Control Mode Wiring The procedure below is illustrated in Figure 2 25 48 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 Connect the positive battery cable to the battery disconnect Connect the negative battery cable to the one of the terminals marked COMMON NEGATIVES Connect a cable between the PV POS LOAD terminal on the controller and the positive terminal on the DC load Connect a cable between the controller s other COMMON NEGATIVES terminal and to the negative terminal of the load Tighten per torque requirements outlined on page 39 Allow a little slack on the cables within the controller and secure the wiring with strain reliefs 975 0004 01 02 Rev D Wiring Common Negatives Battery DC Load Battery DC Load
20. settings retained if battery is disconnected provided for high accuracy Options LCD Meter Panel Back lit 32 character alpha numeric liquid crystal display panel for CM CM R 50 remote CM R or front mounting CM on the C Series controller CM R 100 External Battery Temperature Sensor BTS 15 BTS 35 Provides automatic adjustment of the charge control set point to the battery temperature may be extended 975 0004 01 02 Rev D 71 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 Operating 32 to 104 F 0 to 40 C Temperature Range Specifications at 25 C Non operating 67 to 284 F 55 to 75 C Temperature Specifications at 25 C Altitude Limit 15 000 feet 5 000 meters operating Altitude Limit 50 000 feet 16 000meters non operating Dimensions 8 x5 x2 5 10 x 5 x 2 5 HxWxD 20 3 cm x 12 7 cm x 6 35 cm 25 4 cm x 1 7 cm x 6 35 cm Mounting Vertical Wall Mount Weight Controller 2 5 lbs 1 2 kg 3 0 lbs 1 4 kg 3 0 lbs 1 4 kg only Weight Shipping 3 0 lbs 1 4 kg 3 5 lbs 1 6 g 3 5 lbs 1 6 kg Specifications at 25 C Specifications subject to change without notice 72 975 00
21. sized single conductor to a more convenient location such as a DC load center negative bus if necessary The shunt used to measure the current flow in the C Series controller is located in the positive conductor of the circuit allowing greater flexibility in system grounding The negative terminals are all common to one another 38 975 0004 01 02 Rev D Wiring Terminal Torque Requirements Once the wires have been installed torque the terminals as follows Be careful not to overtighten e 20 inch pounds for 14 10 AWG wire e 25 inch pounds for 8 AWG wire e 35 inch pounds for 6 AWG wire Battery PV Load Negatives Negatives Positive Common to each other Figure 2 21 DC Connection Terminals Wire Size and Over current Protection Requirements The wiring over current protection devices fuses and circuit breakers and installation methods used must conform to all national and local electrical code requirements Wiring should be protected from physical damage with conduit or a strain relief clamp You should pull the temperature sensor cable through the conduit first as the connector may not fit if other wires have been pulled first Current Rating Each model of the C Series controller is rated for a maximum continuous current of 35 40 or 60 amps Since PV outputs can vary due to the array size or sunlight striking it the safe minimum wire size should be based on the maximum current ratings 975 0004 01 02 Rev D 39
22. systems depending upon model as Charge Controller or a Load Controller aR fo TT a f i umep m amry e u Ea v C35 C40 C60 Figure 1 1 C Series Multifunction DC Charge Controllers Numerous features are provided standard to maximize the performance of the system Solid state Pulse Width Modulated PWM charging process with three stage control temperature compensation and manual or automatic equalization to maximize system performance and increase battery life Multi color LED with easy to read mode status label Electronic overload and short circuit protection with automatic and manual reset capability increases the reliability of unattended systems by eliminating blown fuses and tripped circuit breakers Adjustment of charge setpoints is provided by rotary controls potentiometers with removable knobs Calibrated scales and test points allow precise adjustments of settings Over temperature protection for the electronic circuitry when used in hot environments over 113 F 45 C 975 0004 01 02 Rev D 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
23. will not trip or blow when a fault occurs The C Series controller automatically resets the over current protection system every 6 minutes If an overload or short circuit is still present the controller will shut off and wait another 6 minutes This will occur continuously until the problem is corrected 975 0004 01 02 Rev D 59 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 The user can press the reset switch for a maximum 10 minute grace period or can wait until the voltage rises above the Low Voltage Reconnect LVR setting to allow an automatic reset to occur if the EQ LVR Auto jumper is set to AUTO Slow Blinking Orange When the disconnect reconnect system has been activated the LED will slowly blink orange The controller is in the DC Load Control mode and has disconnected the loads due to reaching the LVD setting Reconnecting to Loads To reconnect the loads press the reset button on the right side of the unit If the voltage is below the LVR level the DC load can be reconnect
24. wiring size and length 1 Warning Error or Panel Fault Message Appliances operating when problem occurred O Description of problem 975 0004 01 02 Rev D 89 90 Index A 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 EQ LVR Jumper 21 Equalization Charging 30 Equalization Mode Indication 57 Error Mode Indication 59 F FLOAT charge voltage 23 G Grounding 37 I Information about Your System form 89 J Jumper Settings 18 K Knockouts 14 L LED Status Indicator 55 Load Control Indications 57 Low Voltage Disconnect 25 Low Voltage Reconnect 24 M Manual Equalization 31 National Electrical Code 3 O Operating Mode Jumper 20 Over Current 59 Over Temperature 59 P Photovoltaic Charge Control Mode 7 proof of purchase 89 Pulse Width Modulated 2 purchase date 89 Index R Reset Switch 59 S Safety Instructions vii serial number 89 T Test Points for Voltage Settings 28 Torque Requirements 39 Troublshooting 64 Vv Voltage Jumper 20 WwW 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
25. with Decal for LVR and LVD Settings A decal is provided with the C Series with the proper scale calibrations for the Load Control mode The BULK potentiometer becomes the Low Voltage Reconnect LVR and the FLOAT potentiometer becomes the Low Voltage Disconnect LVD Place the sticker provided over the potentiometers The knobs may have to be removed for sticker placement then reinstalled The sticker is packed inside the C Series controller bottom of unit If the decal is lost or unavailable you can recalculate the appropriate voltage settings as follows The scale for the Low Voltage Reconnect setting is calibrated as follows e 12 volt system 12 0 to 14 0 volts in increments of 0 2 volts e 24 volt system 24 0 to 28 0 volts in increments of 0 4 volts e 48 volt system 48 0 to 56 0 volts in increments of 0 8 volts 24 975 0004 01 02 Rev D Adjusting the C Series Voltage Settings The scale for the Low Voltage Disconnect setting is calibrated as follows e 12 volt system 10 5 to 12 5 volts in increments of 0 2 volts e 24 volt system 21 0 to 25 0 volts in increments of 0 4 volts and e 48 volt system 42 0 to 50 0 volts in increments of 0 8 volts 13 6 a 14 0 ae 13 4 l 8 alb 13 2 nN L V R LOAD 26 4 S L V R LOAD 13 0 D LowVoLTaGE 26 0 2 Low VOLTAGE 128 RECONNECT 25 6 ON RECONNECT 12 6 7 x 25 2 TN T 12 4 1422 12 0 24 8 244 24 0 4 12 3 24 2248 95 Q ec 23 8
26. with a 12 24 or 48 volt DC system however do not expect a 2000 watt power dissipation The power draw is determined by the heater element s DC resistance the output voltage of the controller as well as the output current capability of the charging source s These heater elements were designed to operate at 120 volts AC A 48 volt 40 amp charge controller will operate just fine with this type of a system providing about 500 watts of power dissipation A 12 or 24 volt diversion load controller will work but doesn t put out enough power to effectively heat water with only one element The remedy to this type of problem is to parallel several of these heater elements to increase the power output Table C 1 below shows power dissipation of a 120 Vac 2000 watt heater element operated at different voltages Note that the voltages given are roughly the bulk charge stage voltages for a given system Table C 1 Power Dissipation System Voltage Power Amperage 60 Vdc 48 Vdc system 500 W 8 3 amps 30 Vdc 24 Vdc system 125 W 4 2 amps 15 Vdc 12 Vdc system 31 W 2 1 amps 120 Vac 2000 W 16 7 amps 975 0004 01 02 Rev D 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 go
27. 004 01 02 Rev D vi 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 e All electrical work must be done in accordance with local national and or international electrical codes e Before installing or using this device read all instructions and cautionary markings located in or on this guide the controller the batteries PV array and any other equipment used e This product is designed for indoor mounting only Do not expose this unit to rain snow or liquids of any type In outdoor installations the C Series controller must be installed in a rainproof enclosure to eliminate exposure to rain or water spray To reduce the chance of short circuits use insulated tools when installing or working with the inverter the controller the batteries or any DC source e g PV hydro or wind e Remove all jewelry This will greatly reduce the chance of accidental exposure to live circuits e The controller contains more than one live circuit batteries and PV array wind or hydro Power may be present at more than one source e This product contains no user serviceable parts Do not attempt to repair this unit unless fully qualified 975 0004 01 02 Rev D vii Safety Battery Safety Information
28. 04 01 02 Rev D Batteries Appendix B Batteries describes types of batteries For information on See Battery Types page 74 Battery Sizing page 76 Equalization Charging page 77 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 AN WARNING Explosion Corrosion Hazard 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 Be sure to read the safety precautions on page viii regarding batteries 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 Maintenance Free Batteries This type of battery is often sold as a RV or marine battery but is rarely appropriate for use with a PV system They typically have an additional reserve of electrolyte but are vented This is not the same as a sealed battery Deep Cycle Batteries 74 Best suited for use with PV systems this type of battery is des
29. 1 02 Rev D 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 Front Panel LED flashes red green during equalization i s lt t Press Reset Switch until LED stops alternating A amp wy k between red and Y green Figure 2 19 Terminating the Equalization Charge Temperature Compensation Important If using the C Series as a DC Load Controller e Do NOT compensate the settings e Do not install the Battery Temperature Sensor For optimal battery charging the Bulk and Float charge rates should be adjusted according to the temperature of the battery When battery charging voltages are compensated based on temperature the charge voltage will vary depending on the temperature around the batteries 975 0004 01 02 Rev D 33 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 ba
30. C Series controller The CM R is intended for remote applications These meters provide a digital display of current voltage amperage and amp hours Battery Temperature Sensor BTS The BTS is installed on the side of the battery and attaches to the circuit board inside the C Series controller It provides accurate sensing of the battery temperature and uses this reading to control charging Using this accessory can extend battery life and improve overall charging BTS CM R l CM l Eg Figure 1 7 Optional Accessories CM R CM and BTS 12 975 0004 01 02 Rev D Installation Chapter 2 contains information and procedures to install C Series Multifunction DC Controller For information on See Pre Installation page 14 Mounting the Controller page 16 Configuring the C Series Controller page 18 Adjusting the C Series Voltage Settings page 22 Grounding page 37 Wiring page 38 Installing Optional Accessories page 50 Installing the Battery Temperature Sensor page 51 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
31. ED Blinks Orange after switching on diversion load Diversion load draws too much current above controller Measure the current the diversion load draws when battery voltage is applied breaker or when rating across it diversion begins Bulk Note A diversion load or Float settings with an acceptable hot reached current may have an excessively high inrush current that can cause the controller to overcurrent Caution Do not test without a circuit breaker in circuit Battery voltage is A BTS is A Nothing Intended exceeding Bulk or Float compensating charging operation See settings 66 voltages based on battery temperature B Diversion load is too small for output of charging source s Temperature Compensation on page 33 B Measure the current the diversion load draws when battery voltage is applied across it Caution Do not test without a circuit breaker in circuit A larger diversion load or additional controller each with their own diversion loads may be necessary 975 0004 01 02 Rev D 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 re
32. L WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK Date and Revision November 2003 Revision D Part Number 975 0004 01 02 Rev D Contact Information Telephone 1 800 670 0707 toll free North America 1 360 925 5097 direct Fax 1 800 994 7828 toll free North America 1 360 925 5143 direct Email customerservice xantrex com Web www xantrex com About This Guide Purpose Scope The purpose of this Guide is to provide explanations and procedures for installing operating maintaining and troubleshooting the C Series Multifunction DC Controller 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 You need to consult individual battery manufacturers for this information Audience This Guide is intended for anyone who needs to install and operate the C Series Multifunction DC Controller Installers should be certified technicians or electricians Organization This Guide is organized into four chapters and three appendices Chapter 1 describes features and functions of the C Series Multifunction DC Controller About This Guide Chapter 2 contains information and procedures to install C Series Multifunction DC Controller Chapter 3 con
33. OAD terminal with the BATTERY POSITIVE terminal These terminals must be kept separate You can ONLY ground the battery positive lead in this case if your local jurisdiction allows it This symbol represents a Safety Earth Ground Chassis Ground Lug Figure 2 20 Grounding the C Series Chassis WARNING Shock Hazard Do not disconnect the chassis ground if loads are engaged 975 0004 01 02 Rev D 37 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 AN WARNING Shock Hazard Disconnect battery and PV sources before wiring A CAUTION Damage to Batteries Ensure the voltage selection jumper is set properly before energizing the system Incorrect settings may result in damage to the system as charging regulation will not occur DC Terminal Connector Locations Terminal connectors for DC wiring are located on the lower edge of the circuit board See Figure 2 21 Important Regardless of the configuration only the positive conductor from a PV array OR a DC load may be connected to the terminal marked PV LOAD The common negatives can be reversed or wired with an appropriately
34. PV array If thin film or amorphous solar modules are being used diodes may still be required to prevent damage from partial shading conditions Check the documentation provided with the PV modules Diversion Controller The C Series controller can operate as a Diversion Controller also called a shunt regulator to manage battery charging from alternative energy sources such as PV wind or hydroelectric generators A diversion controller monitors battery voltage and when the voltage exceeds the settings for your charge stage whether bulk or float the power is diverted from the source solar wind or hydro generator to a dump load which will dissipate the excess power into heat When used for this purpose the C Series controller varies an amount of battery voltage to a dump load in order to redirect the excess power generated from over charging the batteries This allows the charging source to remain under constant load to prevent an over speed condition which could occur if the charging source is suddenly disconnected from the battery as series regulators do Consult your dealer for recommendations on diversion load type and regulator size 8 975 0004 01 02 Rev D Controller Functions x Diversion Load h Hydro 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 chargi
35. Product Information Warranty 85 Disclaimer 86 Return Material Authorization Policy 87 Return Procedure 88 Out of Warranty Service 88 Information About Your System 89 Indik ii a 91 xiv 975 0004 01 02 Rev D 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 7 Diversion Controller 9 Load Controller 11 Decal Displaying Load Control Voltage Settings 12 Optional Accessories CM R CM and BTS 12 Removing the Front Cover 14 C Series Dimensions and Knockout Locations Not to Scale 15 Mounting the C Series Multifunction DC Controller 17 Jumper Positions 18 Circuit Board Components 19 Mode of Operation Jumper
36. RT NEGLIGENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW CONDUCT STATEMENT OR OTHERWISE INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A 86 975 0004 01 02 Rev D 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 IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSSES COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND ANY LOSS OR DAMAGE TO PROPERTY ANY PERSONAL INJURY ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE OR THE INCORRECT INSTALLATION INTEGRATION OR OPERATION OF THE PRODUCT Exclusions If this product is a consumer product federal law does not allow an exclusion of implied warranties To the extent you are entitled to implied warranties under federal law to the extent permitted by applicable law they are limited to the duration of this Limited Warranty Some states and provinces do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental or consequential damages so the above limi
37. 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 com 975 0004 01 02 Printed in China
38. aline 16 0 Vdc 14 5 Vdc Not Battery recommended Consult battery manufacturer Values shown are for 12 volt systems For 24 volt Systems multiply this setting shown by 2 For 48 volt systems multiply the settings shown by 4 Important The following settings Table B 1 are guidelines only Refer to your battery vendor for specific settings and battery maintenance guidelines a For NiCad and NiFe batteries you must clip the R46 resistor and add 2 volts to the values for BULK AND FLOAT shown on the circuit board For example set the BULK for 16 0 V adjust the BULK knob to 14 0 V after clipping R46 Values above are for batteries at room temperature For applications with significant temperature variations or systems with sealed batteries install a battery temperature sensor 975 0004 01 02 Rev D 79 80 Diversion Loads Appendix C Diversion Loads provides additional information about Diversion Loads For information on See Diversion Load Types page 82 Diversion Loads Diversion Load Types 82 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 A 120 Vac 2000 watt water heater element available at most hardware stores may be used
39. ample 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 TEST POINTS for DVM center legs of potentiometer Battery Common Negative A A Terminals Figure 2 15 Test Points for Adjusting Voltage Using a DVM 975 0004 01 02 Rev D 29 Installation Equalization Charging 30 A 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 is the deliberate process of charging a battery or battery bank at a high voltage for a set period of time to remix the electrolyte and destratify the internal plates Equalize charging helps to remove sulfate buildup on the battery plates and balances the charge of individual cells Equalization charging holds the voltage above the BULK setting for 2 hours by 1 volt for 12 volt systems 2 volts for 24 volt systems and 4 volts for 48 volt systems The default setting for this feature is MANUAL Automatic equalization is enabled by moving the jumper located on the right side of the
40. an be augmented a little if required This can be accomplished by clipping the wire connecting the R46 Resistor to the circuit board This augmentation will raise the designed charge parameters by 2 volts for 12 volt systems 4 volts for 24 volt systems and 8 volts for 48 volt systems See Figure 2 14 for the augmented voltage settings If using NiCad batteries clip this wire here Do NOT remove the R46 Resistor X R46 Resistor 4 Circuit Board Figure 2 13 R46 Resistor Location 26 975 0004 01 02 Rev D Adjusting the C Series Voltage Settings 16 6 16 8 17 0 33 2 33 6 34 0 a 16 0 0 BULK CHG 205 BULK CHG 130 a he Bet esto 308 30 4 30 0 16 1163 16 5 59 FLOAT CHG FLOAT CHG 30 2 Ba 29 8 294 29 0 14 9 14 7 14 5 12 Volt System Settings 24 Volt System Settings 66 4 87 2 68 0 65 6 ao aa 64 0 BULK CHG 63 2 62 4 61 6 60 8 60 0 66 0 63 6 62 8 62 0 y FLOAT CHG 61 2 60 64 4 65 2 b en 58 8 58 0 48 Volt System Settings C40 only Figure 2 14 Voltage Settings with R46 Resistor Clipped A CAUTION Damage to Batteries It is not recommended to allow an equalize charge to occur if the R46 Resistor is clipped Higher charging voltages may damage the batteries Make sure the EQ LVR jumper is on the MANUAL Setting 975 0004 01 02 Rev D 27 Installation Using a Digital Voltmeter to Adjust Voltage Setting
41. 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 975 0004 01 02 Rev D 75 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 Avoid damage to neighboring components Important In all applications the BULK voltage setting should be adjusted to a level below the maximum operating voltage of the DC loads This may be as low as 15 volts for some types of electronic loads Undercharging may occur in this instance but DC equipment will
42. battery voltage The controller is in the Load Control mode and the battery voltage has reached the Low Voltage Disconnect LVD setting After a 6 minute delay DC loads will be disconnected unless the user reduces the loads to a point that the battery voltage exceeds the LVD setting 975 0004 01 02 Rev D LED Status Indicator Error Mode Indication Orange The C Series Multifunction DC Controller error modes include the following e Over temperature Condition fast flash e Over current Condition fast flash e 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 If excessive temperatures are detected while operating in Charge or Diversion Control mode the controller s transistors are rapidly turned off and on to reduce the charge rate This will reduce the transistor temperature In Load Control mode the load is disconnected before the transistors reach an excessive temperature Once the temperature has dropped the loads are reconnected Over Current Condition During operation the C Series controller continuously monitors the current flowing through it If the current exceeds 85 amps the transistor switches are opened stopping the flow of electricity The detection circuitry is faster than breakers or fuses and they
43. ble 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 Check array output B Set controllers to the same settings C Check wiring D Try a different controller if metering is unacceptable Status LED blinks red while mode jumper is in charge control but still regulates normally LED may have been reinstalled backwards Remove LED and install correctly Flat side of LED should be on left side Battery voltage is exceeding Bulk and Float settings in cold weather and not reaching settings in hot weather 975 0004 01 02 Rev D BTS is compensating charging voltages based on battery temperature Nothing Intended operation See Temperature Compensation on page 33 65 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 L
44. brated Adjusting the C Series Voltage Settings follows e 12 volt system 12 5 to 14 5 volts in increments of 0 2 volts e 24 volt system 25 0 to 29 0 volts in increments of 0 4 volts and e 48 volt system 50 0 to 58 0 volts in increments of 0 8 volts 146148 15 0 14 4 13 6 43 4 13 2 13 0 14 1143 14 5 13 9 13 1 12 9 127 12 5 14 2 28 4 14 0 BULK CHG 28 0 13 8 ER 27 6 13 7 27 4 13 5 FLOAT CHG 27 0 13 3 26 6 12 Volt System Settings 29 2 29 6 30 0 28 8 27 2 26 8 264 26 0 28 2286 99 9 27 8 26 2 258 254 25 0 O BULK CHG 7 FLOAT CHG 24 Volt System Settings 58 4 59 2 60 0 57 6 56 8 56 0 4 BULK CHG 55 2 54 4 53 6 52 8 52 0 56 4572 58 0 55 6 54 8 54 0 ko FLOAT CHG ie ea 50 0 48 Volt System Settings C40 only Figure 2 10 Bulk and Float Charge Settings for Charge Diversion Control Mode 975 0004 01 02 Rev D 23 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 m BULK Setting m 4 LVR Settin Potentiometer 5 SP FLOAT Setting Potentiometer LVD Setting Figure 2 11 Potentiometers
45. e Temperature Compensation on page 33 for information on how to set the voltage Manual or Auto Equalization Charge The C Series controller can be used to manually or automatically provide the battery bank with an equalize charge Factory default setting is for MANUAL Equalization charging Be sure to be familiar with all the cautions and warnings concerning equalization charging batteries or damage to batteries can occur Load Control Mode In the Load Control mode the C Series controls when to remove a load or loads from the system when an over discharge or over load situation occurs The C Series controller uses the user adjustable setpoints to determine when to connect or reconnect loads depending on battery voltage A load controller prevents damage to the battery from over discharge during periods of poor weather or excessive loads The unit does not charge the batteries when in this function 6 975 0004 01 02 Rev D Controller Functions Controller Functions The C Series can be configured to function as three different controllers e PV Charge Controller Charge Control mode e Diversion Controller Charge Control mode e Load Controller Load Control mode Photovoltaic Charge Controller The C Series controller can operate as a Photovoltaic Charge Controller also called a series regulator Depending on the model the controller can regulate up to 60 amps of continuous photovoltaic PV array current at 12
46. e Always wear eye protection such as safety glasses when working with batteries e Remove all jewelry before working with batteries e Never work alone Have someone assist you with the installation or be close enough to come to your aid when working with batteries e Always use proper lifting techniques when handling batteries e Always use identical types of batteries e Never install old or untested batteries Check each battery s date code or label to ensure age and type e Batteries should be installed in a well vented area to prevent the possible buildup of explosive gasses If the batteries are installed inside an enclosure vent its highest point to the outdoors e When installing batteries allow at least 1 inch of air space between batteries to promote cooling and ventilation e NEVER smoke in the vicinity of a battery or generator e Always connect the batteries first then connect the cables to the inverter or controller This will greatly reduce the chance of spark in the vicinity of the batteries e Use insulated tools when working with batteries e When connecting batteries always verify proper voltage and polarity e Do not short circuit battery cables Fire or explosion can occur e In the event of exposure to battery electrolyte wash the area with soap and water If acid enters the eyes flood them with running cold water for at least 15 minutes and get immediate medical attention e Always recycle
47. ed for approximately 6 minutes A delay up to five seconds may occur before the controller attempts to restart after pressing the reset switch Multiple reconnects are allowed but the on time duration will vary with battery voltage The EQUALIZE jumper allows the controller to be set for AUTO reconnect of the DC load when the voltage exceeds the LVR setting 60 975 0004 01 02 Rev D 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 e To manually initiate battery equalization in Charge Control mode press and hold the Reset Switch until the red and green LED start to flash e To manually suspend battery equalization in Charge Control mode press and hold the Reset Switch until the red and green LED stop flashing e To reset following an error condition press and release the Reset Switch e To reset following a low voltage disconnect press and release the Reset Switch See Reconnecting to Loads for additional information about reconnecting to loads Reset Switch aie nas ey S Figure 3 3 Reset Switch 975 0004 01 02 Rev D 61 62 Troubleshooting Chapter 4 Troubleshooting contains information about identifying and resolving possible problems with systems using a C Series Multifunction DC Cont
48. eeeece eee eee eeaeee eee eee se eee eee ee eee Reset Switch on side of unit Multicolor LED indicator E E XAN TEK Charyutned camote w v E anng pO aante armit sil eae A Oo tee Reset Switch Figure 3 1 C Series Status LED and Reset Button Location 54 975 0004 01 02 Rev D 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 e When in Charge Control mode the LED will be green e When in Load Control mode the LED will be red e When an Error Condition exists or the load has disconnected the LED will be orange e When battery equalization is in process the LED alternates between red and green Important The green and red color of the LED only indicates the particular operating mode and the battery voltage level It does not indicate whether the charging source is functioning properly Multicolor LED indicator STATUS Green Blink Charge Control Mode Green Solid Battery Charged Red Blink Load Control Mode Red Solid Battery Discharged Orange Blink Slow Load Disconnected Orange Blink Fast Overload Overtemp Red Green Alternating Equalization Enabled 3 STAGE PULSE WIDTH MODULATED CHARGE CONTROL 35 Amp Controller 12 24 VDC 40 Amp Controller 12 24 48 VDC 60 Am
49. es 16 975 0004 01 02 Rev D Pre Installation A 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 Approximately 1 4 inch Mounting Screws Mounting Surface Secure in place with 2 more screws Figure 2 3 Mounting the C Series Multifunction DC Controller 975 0004 01 02 Rev D 17 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 They must be installed correctly for the unit to operate to its maximum potential To enable a selection carefully slide the jumper over the top of both pins This is called installing the jumper To d
50. f absorbing more power than the C Series controller is designed to handle resulting in an over current shut down During this time the unit will not regulate electrical flow in the system and battery damage may result Load Controller 10 The C Series controller can operate as a Low Voltage Disconnect LVD for DC loads to prevent over discharge to batteries during periods of poor charging or excessive loads The C Series controller uses the user adjustable setpoints to determine when to disconnect or reconnect loads depending on battery voltage When used as a DC load controller the settings of the LVR and LVD are controlled by two rotary potentiometers also called pots on the circuit board The scale on the adjustment potentiometers differ from the scale used for other functions A decal with the appropriate adjustment scale is included with the C Series To apply the decal gently pull off the knobs of the potentiometers and place this decal on the circuit board After the decal is in place replace the knobs The EQ jumper determines manual 975 0004 01 02 Rev D 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 T
51. g Voltage based on Battery Temperature Temperature around the BTS 12 volt units 24 volt units 48 volt units Lead Lead Lead Acid NiCad Acid NiCad 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 60 40 104 0 45 0 30 0 90 0 60 1 80 1 20 35 95 0 30 0 20 0 60 0 40 1 20 0 80 30 86 0 15 0 10 0 30 0 20 0 60 0 40 25 77 0 00 0 00 0 00 0 00 0 00 0 00 20 68 0 15 0 10 0 30 0 20 0 60 0 40 15 59 0 30 0 20 0 60 0 40 1 20 0 80 10 50 0 45 0 30 0 90 0 60 1 80 1 20 5 41 0 60 0 40 1 20 0 80 2 40 1 60 0 32 0 75 0 50 1 50 1 00 3 00 2 00 5 23 0 90 0 60 1 80 1 20 3 60 2 40 10 14 1 05 1 20 2 10 1 40 4 20 2 80 15 5 1 20 0 80 2 40 1 60 4 80 3 20 20 4 1 35 1 40 2 70 1 80 5 40 3 60 25 13 1 50 1 00 3 00 2 00 6 00 4 00 30 22 1 65 1 10 3 30 2 20 6 60 4 40 35 31 1 80 1 20 3 60 2 40 7 20 4 80 40 40 1 95 1 30 3 90 2 60 7 80 5 20 975 0004 01 02 Rev D 35 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 automatica
52. he 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 stratification Two methods can be used to determine if a battery needs to be equalized If possible measure the voltage of each individual cell while the battery is at rest not being charged or discharged A variation of 0 05 volts between cells 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 975 0004 01 02 Rev D 77 Batteries 78 A CAUTION Damage to Batteries Equalization should be done only on vented not sealed
53. he product or costs related to the removal installation or troubleshooting of the customer s electrical systems This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to a the product if it has been misused neglected improperly installed physically damaged or altered either internally or externally or damaged from improper use or use in an unsuitable environment b the product if it has been subjected to fire water generalized corrosion biological infestations or input voltage that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex product specifications including high input volt age from generators and lightning strikes c the product if repairs have been done to it other than by Xantrex or its authorized ser vice centers hereafter ASCs d the product if it is used as a component part of a product expressly warranted by another manufacturer e the product if its original identification trade mark serial number markings have been defaced altered or removed Disclaimer Product THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS WHERE PERMITTED BY LAW IN LIEU OF ALL OTHER WARRANTIES CONDITIONS GUARANTEES REPRESENTATIONS OBLIGATIONS AND LIABILITIES EXPRESS OR IMPLIED STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT HOWEVER ARISING WHETHER BY CONTRACT TO
54. here will be a 6 minute delay after the voltage drops below the Low Voltage Disconnect LVD setting before the controller actually disconnects the load Low Voltage Reconnect It can also provide automatic reconnection of the loads at the LVR Low Voltage Reconnect setting Reconnection of the load is allowed once the battery voltage has exceeded the Low Voltage Reconnect LVR setting Loads are either automatically or manually reconnected when battery voltage exceeds the Low Voltage Reconnect LVR setting for 6 minutes See Operating Mode Jumper on page 20 for instructions on enabling this mode oan eo00ce eo ee gt C Saries gt OC Load gt Murtonction DC Controlle cooo econ coco ee la amp Figure 1 5 Load Controller Important When using the DC Load Control mode Do not temperature compensate these settings e Do not install the optional battery temperature compensation sensor 975 0004 01 02 Rev D 11 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
55. ifunction DC Controller has expired if the unit was damaged by misuse or incorrect installation if other conditions of the warranty have not been met or if no dated proof of purchase is available your inverter may be serviced or replaced for a flat fee To return your C Series Multifunction DC Controller for out of warranty service contact Xantrex Customer Service for a Return Material Authorization RMA number and follow the other steps outlined in Return Procedure on page 88 Payment options such as credit card or money order will be explained by the Customer Service Representative In cases where the minimum flat fee does not apply as with incomplete units or units with excessive damage an additional fee will be charged If applicable you will be contacted by Customer Service once your unit has been received 88 975 0004 01 02 Rev D 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 C Purchased From 1 Purchase Date If you need to contact Customer Service please record the following details before calling This information will help our representatives give you better service Type of installation e g RV truck vehicle home Length of time inverter has been installed C Battery battery bank size O DC
56. igned 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 975 0004 01 02 Rev D 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 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 popular and inexpensive deep cycle battery is the golf cart battery It is a 6 volt design typically rated at 220 amp hours RV and marine deep cycle batteries are also popular for small systems They are usually referred to as Group 24 or Group 27 batteries and are rated at 80 to 100 amp hours at 12 volts Many larger systems use L16 batteries which are usually rated at 350 amp hours at 6 volts each They are 17 inches high and weigh about 130 pounds 8D batteries are available with either cranking or deep cycle construction Purchase only the deep cycle version The 8D is typically rated at 220 amp hours at 12 volts Sealed Batteries Another type of
57. is 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 To set the voltage place the jumper over the two pins adjacent to the legend for the voltage of your system 12 24 48 Factory setting is 12 volts for the C35 C40 and C60 C40 Models lt q 12 Volt Position t 24 Volt Position 1 amp 48 Volt Position C35 and C60 Models 12 Volt Position wat 24 Volt Position Figure 2 7 Voltage Selection Jumper 20 975 0004 01 02 Rev D 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 e automatic or manual battery equalization Charge Control mode or e 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 This can be done manually by using Reset Switch on the side of the controller chassis When AUTO is enabled in Load Control mode the unit will reconnect automatically when voltage at the BATTERY POSITIVE terminal exceeds the LVR setting This can also be done manually by using Reset Switch on the side of the controller chassis The factory default setting is MANUAL EQUALIZATION Charge Control mode Place the jumper over the pin
58. isable a selection carefully slide the jumper over only one of the pins This is called removing the jumper Jumper Removed Jumper is only on one pin Jumper Jumper Installed Jumper is on both pins Figure 2 4 Jumper Positions The factory default settings are shown in Table 2 1 Factory Default Settings for C Series Controllers on page 19 Important Use extreme caution when installing and removing jumpers so as not to bend the pins 18 975 0004 01 02 Rev D 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 a EQ LVR Jumper lt Operating i Mode 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 board over the potentiometers Figure 2 5 Circuit Board Components 975 0004 01 02 Rev D 19 Installation Operating Mode Jumper This jumper determines the operating mode Place the jumper over the pins that correspond to the desired mode e Charge Control PV Charge Controller or Diversion Controller e Load Control Load Controller Factory default setting is Charge Control mode Charge Load Control Jumper
59. l end user customer You require proof of purchase to make warranty claims This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period Subsequent owners also require proof of purchase What will Xantrex do Xantrex will at its option repair or replace the defective product free of charge provided that you notify Xantrex of the product defect within the Warranty Period and provided that Xantrex through inspection establishes the existence of such a defect and that it is covered by this Limited Warranty Xantrex will at its option use new and or reconditioned parts in performing warranty repair and building replacement products Xantrex reserves the right to use parts or products of original or improved design in the repair or replacement If Xantrex repairs or replaces a product its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipment to the customer whichever is greater All replaced products and all parts removed from repaired products become the property of Xantrex Xantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a Xantrex selected non expedited surface freight within the contiguous United States and Canada Alaska and Hawaii are excluded Contact Xantrex Customer Service for details on freight policy for return shipments outside of the contiguous United
60. lay to disable the diversion load while using a generator Diversion load operates immediately at full power when load breaker is turned on 975 0004 01 02 Rev D Mode jumper is set for Load Control instead of Charge Control Change jumper setting 67 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 Battery Temperature Sensors should not be used in load control applications Status LED Blinks Orange after switching on the load breaker 68 Startup or Inrush current exceeds controller rating Use larger controller or buffer the controller by using a relay contactor where the controller operates only the coil of the relay contactor and not directly to the DC load 975 0004 01 02 Rev D Specifications Appendix A Specifications provide the specifications for the C Series Multifunction DC Controller For information on See Electrical Specifications page 70 Features and Options Specifica
61. lly decreases Manual Battery Temperature Compensation 36 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 The recommended adjustments can be made following Table 2 2 The setting should be lowered for ambient temperatures above 86 F 30 C and raised for ambient temperature below 68 F 20 C If significant seasonal variations are common you will have to change the settings several times a year to prevent battery damage and ensure proper operation Important If the wiring to the sensor is damaged and the wires are shorted or cut the system will return to the non temperature compensated settings 975 0004 01 02 Rev D 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 Consult local and national electrical codes for more information and any additional requirements Telecom applications often require a positive ground system The C Series controller switches the PV L
62. n 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 Split bolt kerneys can also be used for wire splices Follow manufactures recommendations for torque and mounting if required Splicer blocks and split bolt kerneys are available from renewable energy suppliers Maximum One way Distance and Wire Size Important NEC Article 690 and local electrical codes should be consulted for wire sizing and any additional installation requirements e Fora C60 use a 60 amp 100 Continuous Duty breaker and 6 AWG 90 C wire e Larger wire sizes may be used to improve performance but are NOT approved by UL to be installed in the controller Use a splicer block as previously described Refer to Table 2 4 and find your maximum current in the left column and the one way distance from your power source feet meters to the C Series controller or the distance from the C Series controller to your load on the same line then read the wire size required at the top of the column 42 975 0004 01 02 Rev D Table 2 4 One Way Wire Distance and Wi
63. ng 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 Light bulbs and motors are not recommended as diversion loads because they are unreliable A diversion load that draws about 25 more current than the charging source s maximum output capability is usually suitable for use with the C Series controller See Appendix C Diversion Loads for additional information on types of diversion loads See Operating Mode Jumper on page 20 for instructions on enabling this mode 975 0004 01 02 Rev D 9 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 A diversion load that is too small will not be able to absorb all the excess power from the current source once the batteries are full allowing batteries to overcharge Diversion loads in excess of the controller s rating are capable o
64. od rule of thumb is to not have a combined charging source greater than 80 of the diversion load controller s current handling ability For example if a Xantrex C Series 40 amp diversion load controller is being used do not place a combination of charging sources which are capable of putting out more than 32 amps 80 of 40 amps on the load controller s circuit Sizing a diversion system this way allows a safety margin for unusual conditions high winds high water flow etc It is not recommended that light bulbs be used as diversion loads for a couple of reasons 1 An incandescent light bulb has a substantially lower cold filament resistance than when it is on This means it draws more power up to five times to start the light when it is cold than once the filament has warmed up Even a 40 watt light bulb may have an in rush amperage at turn on of 200 amps This could cause the load controller to shut down 2 Inthe event a light bulb load burns out a smaller than necessary load will be present and the excess energy will have nowhere to go 975 0004 01 02 Rev D 83 84 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 C Series Multifunction DC Controller This warranty period lasts for two years from the date of purchase at the point of sale to you the origina
65. on devices are recommended Put the surge protection device for this scenario on the battery input line between the battery and the controller Over current Protection The NEC requires conductors and over current devices be operated at no more than 80 of their rating Refer to Table 2 3 for a listing of the minimum wire size and over current device ratings to be used for each model As a minimum a 60 amp DC rated current limiting fuse or circuit breaker should be installed near the battery for protection from short circuits To meet NEC requirements use a 60 amp circuit breaker listed for 100 duty for the C60 To meet UL requirements use 6 AWG copper wires rated for 90 C 194 F for the C60 Over current protection for the battery circuit is to be provided by others Refer to Table 2 3 for the correct ratings of the fuse and circuit breaker Table 2 3 Minimum Wire Size Controller Minimum Wire Size Over Current Device Rating C35 8 AWG 45 amps C40 8 AWG 50 amps C60 6 AWG 90 C 194 F wire 60 amps listed 100 duty C60 4 AWG 75 C 167 F wire 60 amps listed 100 duty a To meet UL requirements use 6 AWG 90 C 194 F wire and a 60 amp Listed 100 duty over current device for the C60 controller b Not approved by UL for direct connection into the controller Use a splicer block and 6 AWG 90 C 194 F wire to connect to the controller terminals 975 0004 01 02 Rev D 41 Installatio
66. 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 CAUTION Damage to Loads DC loads may need to be disconnected by turning off circuit breakers or removing fuses before equalization to prevent damage by the required higher voltages used in the equalization process CAUTION If the batteries are equipped with hydro caps catalytic gas recombiner caps they should be removed during the equalization process If hydro caps are used you should disable automatic equalization to prevent possible damage 975 0004 01 02 Rev D Equalization Charging Equalization Setpoints Non Sealed Batteries Only Table B 1 Typical Bulk and Float Setpoints for Batteries Equalizing Battery Type Bulk Volts Float Volts Charge Default Settings knobs 14 0 Vdc 13 5 Vdc Disabled at nine o clock position manual jumper Sealed Gel Lead Acid 14 1 Vdc 13 6 Vdc Non Battery recommended Consult Battery manufacturer AGM Lead Acid 14 4 Vdc 13 4 Vdc Charge to Battery 15 5 Vdc or per manufacturer Maintenance Free 14 4 Vdc 13 4 Vdc Limited RV Marine appropriateness if water level can be checked Deep Cycle Liquid 14 6 Vdc 13 4 Vdc Charge to Electrolyte Lead 15 5 Vdc or per Antimony Battery battery manufacturer NiCad or NiFe Alk
67. orption 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 Float Stage During this stage the voltage of the battery is held at the float voltage setting Full current can be provided to the loads connected to the battery during the float stage from the PV array When battery voltage drops below the float setting for a cumulative period of one hour a new bulk cycle will be triggered Bulk Stage Absorption Stage Float Stage Charging Bulk Volts Setting Started Absorption Time Float Volts Setting DC Voltag Increasing Voltage Constant Voltage Reduced Voltage DC Current Constant Current Reducing Current Reduced Current Figure 1 2 3 stage Battery Charging Process 975 0004 01 02 Rev D 5 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 If not using the BTS the voltage settings for charging will need to be adjusted based on the temperature of the environment around the batteries and on the type of batteries being used Se
68. p Controller 12 24 VDG Xa ntrex Charge Load Controller C 5916 195th STREET NE ARLINGTON WASHINGTON 98223 TELEPHONE 360 435 8826 FAX 360 435 2229 ch Figure 3 2 C Series Front Panel Label 975 0004 01 02 Rev D 55 Operation Table 3 1 Battery Voltage LED Indicators Green LED LED Red LED Charge Diversion Mode Status Load Control Mode Battery at FLOAT Setting Always Battery at LVD Setting ON for 6 minutes LVD Battery at BULK Setting 5 blinks gt 0 15 gt 0 03 gt 0 45 above above above LVD LVD LVD BULK Setting Minus LVD Setting Plus 0 25 Vde 0 50Vde 1 00 Vde 4blinks 0 15 Vde 0 30 Vdc 0 45 Vdc 0 50 Vdc 1 00 Vde 2 00 Vde 3 blinks 0 30 Vde 0 60 Vdc 0 90 Vdc 0 75 Vdc 1 50 Vde 3 00 Vdc 2blinks 0 45 Vdc 0 90 Vde 1 35 Vdc gt 0 75 gt 1 50 gt 3 00 1blink gt 0 45 gt 0 90 gt 1 375 below Bulk below Bulk below Bulk below Bulk below Bulk below Bulk 12 volts 24 volts 48 volts DC 12 volts 24 volts 48 volts Voltage Charge Control or Diversion Control Indications Green 56 The flashing rate of the LED indicates the controller s stage of operation and approximate battery voltage e One to four flashes indicates the controller is in the Bulk stage As the flashing rate increases the batteries are progressively closer to the Bulk voltage Table 3 1 indicates the approximate level the battery is below the Bulk se
69. 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 Removing the Top Cover Access the inside of the controller by removing the four phillips screws 10 32 x 3 8 SMS screws on the front cover of the unit Remove these phillips screws x4 from the front cover to access the inside of the controller Figure 2 1 Removing the Front Cover Removing Knockouts Six dual knockouts are provided to accommodate the necessary wiring of the C Series controller Be sure to remove any metal shavings created by removing the 14 975 0004 01 02 Rev D 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 Heatsink not Keyhole Slots for included on C35 mounting Nl 51 mm i O O Additional Mounting Holes x4 203 mm 6 7 8 174 mm 203 mm Ye and 3 4 Dual Knockouts s or 2 lt 3 5 8 gt _ 64 mm ial 93 mm 5 127 mm O This distance varies per model C35 3 8 C40 C60 5 8 2 3 4 and 1 Dual Knockouts x4 1 on each side and 2 on the bottom of chassis Figure 2 2 C Series Dimensions and Knockout Locations Not
70. r monitors the batteries and depending on how it is wired will regulate the PV current as a PV Charge Controller or divert excess energy from PV hydro or wind to a DC load as a Diversion Controller and allows the battery to charge according to user defined settings based on the amount of DC power available When the C Series operates in the Charge Control mode it provides e three stage charging of battery voltage e automatic temperature compensation if the BTS is used and e automatic or manual equalization charging Three Stage Battery Charging The three stage charging process results in faster charging compared to on off relay type or constant voltage solid state regulators Faster recharging increases the performance of the system by storing more of the PV array s limited output The final float voltage setting reduces battery gassing minimizes watering requirements and ensures complete battery recharging The C Series will use this protocol in either PV Charge Control mode or in Diversion Control mode It does not charge the batteries when in Load Control mode Battery voltage and current vary during the three stage charging process as follows 975 0004 01 02 Rev D 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 abs
71. re Size Maximum One way Wire Distance for a lt 3 Voltage drop 12 Vdc Application Shown For 24 Vdc Systems Multiply distance by 2 For 48 Vdc Systems Multiply distance by 4 Wiring Distance in Feet meters Distance in Feet Meters Amps 12 10 8 6 4 3 2 1 1 0 2 0 P AWG AWG AWG AWG AWG AWG AWG AWG AWG AWG 10 8 8 ft 14 ft 22 2 ft 353f 56 1ft 709f oof 112 5ft 141 7 ft 225 8 ft 268m 4 27m 6 77m 10 76 m 17 10m 21 61 m 27 31 m 34 29 m 43 19 m 68 82 m 12 7 3 ft 6f iss 294f 4o7 soi1ft 746f 93 78 18i t 188 2 ft 2 23m 8 54m 5 64m 896m 14 23m 18 01 m 22 74 m 28 56 m 36 00 m 57 36 m 14 6 3 ft 10 ft 15 9ft 252f 40 1ft so6f 640f 804f 1012 ft 161 3 ft 1 92m 6 05m 4 85m 7 68m 12 22 m 15 42 m 19 51 m 24 51 m 0 85 m 49 16 m 16 5 5 ft 8 7 ft 13 9f 221f 35 0f 443f 56 0ft 703f 88 oft 141 2 ft 1 68 m 2 65m 4 24m 674m 10 67 m 13 50 m 17 07 m 21 43 m 27 01 m 43 04 m 18 4 9 ft 8 8 ft 24f 196f 312 39 4ft 498f 62 5ft 78 7f 125 5 ft 149m 238m 6 78m 597m 9 51m 12 01 m 15 18 m 19 05 m 23 99 m 38 25 m 20 44 ft 7ft if 176f 28 0ft 35 4f 44 8ft 562f 70 9ft 1129 ft 134m 2 13m 6 38m 5 36m 8 53m 10 79 m
72. rging or their state of charge Solid Green The battery is being charged in the FLOAT stage The status LED remains ON solid unless the batteries drop below the float voltage setting for an accumulative period of one hour This allows the user to confirm that the system reached the float stage during the charging process when checked at the end of the day Reaching the float stage frequently is a good indication of proper system operation and will maximize battery life and performance 975 0004 01 02 Rev D 57 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 The user can manually stop the equalization process at any time by pressing the reset switch until the status LED stops alternating red and green Load Control Indications Red The flashing rate of the LED indicates the controller s stage of operation and approximate battery voltage Blinking Red Solid Red 58 As battery voltage approaches the LVD setting the LED will blink red several times up to five and then pause providing an indication of battery voltage Refer to Table 3 1 to determine the
73. roller For Information on See PV Charge Control Troubleshooting page 64 Diversion Control Troubleshooting page 66 Load Control Troubleshooting page 68 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 Controller is locking up PV positive and Battery positive wires have been swapped Verify the voltage on PV terminal and Battery terminal are from the correct sources Status LED Blinks Orange after switching on array breaker PV wires are connected in reverse polarity Verify PV polarity relative to battery negative Status LED Blinks Orange at times during the solar day 64 A Controller is overheating B Array is supplying more current than the controller is rated for Press reset button and measure current A Check ambient air temperature around controller B Divide array with another controller or use larger controller 975 0004 01 02 Rev D PV Charge Control Troubleshooting Ta
74. rolyte and charge the cells These cycles should follow one another until the battery voltage reaches the upper limit for the full two hours 975 0004 01 02 Rev D 31 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 The battery voltage only needs to exceed the bulk setting for the timer to start counting the voltage may not reach the equalization voltage setting To enable automatic equalization the jumper located on the right side of the circuit board must be moved to the AUTO setting The default setting of the C Series controller is for manual equalization To disable the automatic equalization system move the equalize jumper to MANUAL Senn Manual Equalize permit ony Sci ii i 3 m Auto Equalize Figure 2 18 Auto Equalization Settings Once a manual equalization has been triggered the 30 day period to the next automatic equalization will be restarted To prevent automatic equalization move the equalize jumper to the manual position Important Itis not recommended to use the Equalization feature if the R46 Resistor is clipped 32 975 0004 0
75. rt on the lower right corner of the circuit board inside the C Series controller Important Ventilate the battery box at the highest point to prevent hydrogen accumulation Battery Temperature Sensor Port RJ 11 Port C Series Circuit Board Route the e x E inverter s BTS R11 Pot 4 Fi Battery Temperature Sensor ot Appty the Battery Temperature Sensor to the side of the bamery 975 0004 01 02 Rev D 51 Figure 2 27 Installing the BTS 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 Figure 2 28 Re installing the CM Faceplate 52 975 0004 01 02 Rev D Operation Chapter 3 contains information about the operation of a C Series Multifunction DC Controller For Information on See Basic Operation page 54 LED Status Indicator page 55 Charge Control or Diversion Control page 56 Indications Green Load Control Indications Red page 58 Error Mode Indication Orange page 59 Reconnecting to Loads page 60 Operation Basic Operation The C Series controller all models has one multicolor LED status indicator and one reset button u eee e
76. s 28 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 Point the potentiometers to the mid range position 2 Connect a digital voltmeter from one of the common negative terminals on the circuit board and the small test point located to the left of each potentiometer at the nine o clock position See Figure 2 15 The test point provides a reading from 0 to 2 volts Multiply this value by 2 for 24 volt system and by 4 for 48 volt system 3 Add the value obtained in step 2 above to the lower value of the adjustment range voltage scale being used For example for a 12 volt system To set the BULK voltage to 14 4 volts 1 Point the BULK potentiometer to the mid range position 2 Adjust the potentiometer until the DVM displays 1 4 volts 13 0 V 1 4 V 14 4 V For example for a 24 volt system To set BULK voltage to 28 2 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 2 24 volt 2 2 26 0 28 2 975 0004 01 02 Rev D Adjusting the C Series Voltage Settings For ex
77. s for the desired selection EQ LVR Jumper MANUAL AUTO Figure 2 8 EQ LVR Jumper and Reset Switch See Error Mode Indication Orange on page 59 for instructions on how to use the Reset Switch in relation to this function 975 0004 01 02 Rev D 21 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 For more information regarding bulk and float charging voltages see Three Stage Battery Charging on page 4 Setting indicator Scale Marks Potentiometers Figure 2 9 Bulk and Float Charge Potentiometers pots Setting Voltage Parameters for Charge Control Mode To set the controller to a specific voltage point the setting indicator at the scale mark representing the desired voltage The potentiometer scale for BULK charge voltage is calibrated as follows e 12 volt system 13 0 to 15 0 volts in increments of 0 2 volts e 24 volt system 26 0 to 30 0 volts in increments of 0 4 volts e 48 volt system 52 0 to 60 0 volts in increments of 0 8 volts 22 975 0004 01 02 Rev D For FLOAT charge voltage the potentiometer scale is cali
78. t Button Location 54 C Series Front Panel Label 55 Reset Switch 61 975 0004 01 02 Rev D 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 19 Variances in Charging Voltage based on Battery Temperature 35 Minimum Wire Size 41 One Way Wire Distance and Wire Size 43 Battery Voltage LED Indicators 56 PV Charge Control Problems 64 Diversion Control Problems 66 Load Control Problems 68 Electrical Specifications 70 Features and Options Specifications 71 Environmental Specifications 72 Typical Bulk and Float Setpoints for Batteries 79 Power Dissipation 82 xvii xviii Introduction Chapter describes features and functions of the C Series Multifunction DC Controller For information on See Features page 2 Operating Modes page 3 Controller Functions page 7 Optional Accessories page 12 Introduction Features The C35 C40 C60 C Series controllers can be used with 12 volt 24 volt or 48 volt DC
79. tains 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 Appendix B Batteries describes types of batteries Appendix C Diversion Loads provides additional information about Diversion Loads Conventions Used The following conventions are used in this guide WARNING Warnings identify conditions that could result in personal injury or loss of life CAUTION Cautions identify conditions or practices that could result in damage to the unit or to other equipment Important These notes describe an important action item or an item that you must pay attention to iv 975 0004 01 02 Rev D 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 975 0
80. tation s or exclusion s may not apply to you This Limited Warranty gives you specific legal rights You may have other rights which may vary from state to state or province to province Warning Limitations On Use Please refer to your product manual for limitations on uses of the product SPECIFICALLY PLEASE NOTE THAT THE C SERIES MULTIFUNCTION DC CONTROLLER SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES WITHOUT LIMITING THE GENERALITY OF THE FOREGOING XANTREX MAKES NO REPRESENTATIONS OR WARRANTIES REGARDING THE USE OF THE XANTREX C SERIES MULTIFUNCTION DC CONTROLLER IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES Return Material Authorization Policy Before returning a product directly to Xantrex you must obtain a Return Material Authorization RMA number and the correct factory Ship To address Products must also be shipped prepaid Product shipments will be refused and returned at your expense if they are unauthorized returned without an RMA number clearly marked on the outside of the shipping box if they are shipped collect or if they are shipped to the wrong location When you contact Xantrex to obtain service please have your instruction manual ready for reference and be prepared to supply The serial number of your product Information about the installation and use of the unit Information about the failure and or reason for the return A copy
81. tions page 71 Environmental Specifications page 72 Specifications Electrical Specifications The following lists the electrical specifications for the C Series controllers Models C35 C40 and C60 Table A 1 Electrical Specifications Model C35 c40 c60 Voltage 12 Vdc 24 Vdc 12 Vde 24 Vde 48 Vde 12 Vdc 24 Vdc Configuration Maximum PV 55 Vdc 55 Vdc 125 Vde 125 Vdc 125 Vdc 55 Vdc 55 Vde Array Open Circuit Voltage Charging Load 35 amps DC 40 amps DC continuous 60 amps DC Current continuous continuous Recommended 60 amps DC 60 amps DC 60 amps DC Breaker Size with 6 AWG 6 AWG 100 continuous recommended duty cycle Wire Size in 6 AWG Conduit 90 C rated Maximum Short 85 amps 85 amps intermittently 85 amps Circuit Current intermittently intermittently Maximum Voltage Drop 0 30 volts charge control mode Total Current While operating 15 mA typical at idle 3 mA tare Consumption Charger Regulation Solid state 3 stage bulk absorption and float Pulse Width Modulation Method PWM Charging Control Settings Lead Acid Battery 12 Volt System 24 Volt System 48 Volt System Float 12 5 14 5 Vdc Float 25 0 29 0 Vdc Float 50 0 58 0 Vde Bulk 13 0 15 0 Vdc Bulk 26 0 30 0 Vdc Bulk 52 0 60 0 Vdc EQ 1 above Bulk EQ 2 above Bulk EQ 4 above Bulk NiCad battery 12 Volt System 24 Volt System 48 Volt System 70
82. to Scale 975 0004 01 02 Rev D 15 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 A CAUTION Damage to C Series Controller Install the C Series controller in a dry protected location away from sources of high temperature moisture and vibration Exposure to saltwater is particularly destructive Corrosion is not covered by the warranty To mount the C Series controller 1 Remove the faceplate on the controller 2 Place the controller on the desired mounting surface and mark the location of the keyhole slots on the wall 3 Move the controller out of the way and secure two mounting screws in the locations marked Leave the screw heads backed out approximately 1 4 inch 6 mm or less 4 Place the controller onto the screws and pull it down into the keyhole slots 5 Then insert the two more screws in two of the four additional mounting holes provided to secure the enclosure onto the wall 6 Provide either strain relief clamps or conduit to prevent damage to the circuit board and terminal block from pulling on the wir
83. tteries 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 If the R46 resistor is cut the temperature compensation charging voltage will be based on Alkaline type batteries See the battery type below to determine the temperature compensation value change per temperature or refer to the temperature compensation calculations for a Lead Acid type battery as show in Table 2 2 e Lead Acid Type Batteries 5 mV per cell per degree Celsius e Alkaline Type Batteries NiCad or NiFe 2 mV per cell per degree Celsius Table 2 2 describes approximately how much the voltage may vary depending on the temperature of the batteries Automatic Battery Temperature Compensation Temperature compensation can be accomplished automatically by using a Battery Temperature Sensor BTS The sensor attaches directly to the side of one of the batteries in the bank and provides precise battery temperature information See Installing the Battery Temperature Sensor on page 51 for detailed instructions on how and where to install the BTS If a BTS is installed the charge controlling process will be automatically adjusted for the battery temperature When using a BTS set the Bulk and Float voltage for a battery at normal room temperature for 77 F 25 C 34 975 0004 01 02 Rev D Temperature Compensation Table 2 2 Variances in Chargin
84. tting e Five flashes indicates the controller has reached Bulk voltage and is in the Absorption stage e Solid green means the controller is in the Float stage and is regulated at the Float voltage 975 0004 01 02 Rev D 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 5 volts 28 volts Bulk setting minus gt 1 50 volts in the table Important LED will light green only in Diversion and Charge Control mode unless it is reinstalled backwards Blinking Green The controller is in the Charge Control or Diversion Control mode and the battery is not fully charged As the battery voltage approaches the BULK setting the status LED will blink green several times up to five and then pause indicating the battery voltage is approaching the bulk setting and provides an indication of the battery condition Refer to Table 3 1 to determine the battery voltage Important A single green flash indicates the battery is well below the bulk voltage setting It does NOT indicate the batteries are cha
85. urface 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 10 Connect the PV array s positive output to the PV array disconnect Route another cable from the other end of the RE disconnect to the PV GFP Route another cable from the same switch in the PV GFP to the terminal marked PV POS LOAD in the C Series controller Connect the PV array s negative output to the terminal marked COMMON NEGATIVES Connect another negative cable from the other COMMON NEGATIVES to the Negative bus in the DC disconnect Route a negative wire from the PV GFP to the Negative bus in the DC disconnect Connect a positive cable from terminal marked BAT POS to the battery disconnect in the DC disconnect Connect a second positive cable to the other side of the battery disconnect in the DC disconnect and connect to the positive battery terminal Connect the negative battery cable to the negative bus in the DC disconnect and tighten the lugs Tighten per torque requirements outlined on page 39 Allow a little slack on the cables within the controller and secure the wiring with strain reliefs 975 0004 01 02 Rev D Wiring Common Negatives Battery PV Array Battery PV Array Positive Positive Negative Negative

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