Xantrex C35 - Manuals

975-0004-01-02 Rev D vii Important Safety Instructions General Safety Instructions • All electrical work must be done in accordance with local, national, and/or international electrical codes. • Before installing or using this device, read all instructions and cautionary markings located in (or on) ...

Safety viii 975-0004-01-02 Rev D Battery Safety Information • Always wear eye protection, such as safety glasses, when working with batteries. • Remove all jewelry before working with batteries. • Never work alone. Have someone assist you with the installation or be close enough to come to your aid ...

xi Important Safety Instructions - - - - - - - - - - - - - - - - - - vii 1 Introduction Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 Operating Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 Charge Control Mode - - - - - - - - - -...

Contents 975-0004-01-02 Rev D xiii 3 Operation Basic Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54 LED Status Indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55 Charge Control or Diversion Control Indications (Green) - - 56 Blinking Green - - - - ...

Contents xiv 975-0004-01-02 Rev D Battery Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76 Equalization Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77 Equalization Setpoints (Non-Sealed Batteries Only) - - - - - - 79 C Diversion Loads Diversion Loa...

xv Figure 1-1 C-Series Multifunction DC Charge Controllers - - - - - - 2 Figure 1-2 3-stage Battery Charging Process - - - - - - - - - - - - - - - 5 Figure 1-3 PV Charge Controller - - - - - - - - - - - - - - - - - - - - - - - 7 Figure 1-4 Diversion Controller - - - - - - - - - - - - - - - - - - - -...

xvii Table 2-1 Factory Default Settings for C-Series Controllers - - - - 19 Table 2-2 Variances in Charging Voltage based on Battery Temperature - - - - - - - - - - - - - - - - - - - - - - - 35 Table 2-3 Minimum Wire Size - - - - - - - - - - - - - - - - - - - - - - - 41 Table 2-4 One-Way Wire Distan...

1 Introduction Chapter 1 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 2 975-0004-01-02 Rev D Features The C35/C40/C60 ( C-Series ) controllers can be used with 12-volt, 24-volt, or 48-volt DC systems (depending upon model) as Charge Controller or a Load Controller. Numerous features are provided standard to maximize the performance of the system: • Solid-...

Operating Modes 975-0004-01-02 Rev D 3 • 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 ...

Introduction 4 975-0004-01-02 Rev D 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 c...

Operating Modes 975-0004-01-02 Rev D 5 Bulk Stage During this stage, the batteries are charged at the bulk voltage setting and maximum current output of the DC source. When the battery voltage reaches the bulk voltage setting, the controller activates the next stage (absorption). Absorption Stage Du...

Introduction 6 975-0004-01-02 Rev D 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 temp...

Controller Functions 975-0004-01-02 Rev D 7 Controller Functions The C-Series can be configured to function as three different controllers: • PV Charge Controller (Charge Control mode) • Diversion Controller (Charge Control mode) • Load Controller (Load Control mode) Photovoltaic Charge Controller T...

Introduction 8 975-0004-01-02 Rev D 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 Ju...

Introduction 10 975-0004-01-02 Rev D Load Controller 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 w...

Controller Functions 975-0004-01-02 Rev D 11 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 cont...

Introduction 12 975-0004-01-02 Rev D 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 fa...

2 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 “Ground...

Installation 14 975-0004-01-02 Rev D 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. Removin...

Installation 16 975-0004-01-02 Rev D 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 mounte...

Installation 18 975-0004-01-02 Rev D 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. ...

Configuring the C-Series Controller 975-0004-01-02 Rev D 19 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 Figure 2-5 Circuit Board Components Operating Mode Jumper Reset ...

Installation 20 975-0004-01-02 Rev D Operating Mode Jumper This jumper determines the operating mode. Place the jumper over the pins that correspond to the desired mode. • Charge Control (PV Charge Controller or Diversion Controller) • Load Control (Load Controller) Factory default setting is Charge...

Configuring the C-Series Controller 975-0004-01-02 Rev D 21 Automatic/Manual Battery Equalization (EQ) and Low Voltage Reconnect (LVR) Jumper Depending on the mode of operation chosen, this jumper enables: • automatic or manual battery equalization (Charge Control mode), or • automatic or manual rec...

Installation 22 975-0004-01-02 Rev D 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-adjustmen...

Adjusting the C-Series Voltage Settings 975-0004-01-02 Rev D 23 For FLOAT charge voltage, the potentiometer scale is calibrated follows: • 12-volt system: 12.5 to 14.5 volts in increments of 0.2 volts, • 24-volt system: 25.0 to 29.0 volts in increments of 0.4 volts, and • 48-volt system: 50.0 to 58....

Installation 24 975-0004-01-02 Rev D 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’...

Adjusting the C-Series Voltage Settings 975-0004-01-02 Rev D 25 The scale for the Low Voltage Disconnect setting is calibrated as follows: • 12-volt system: 10.5 to 12.5 volts in increments of 0.2 volts, • 24-volt system: 21.0 to 25.0 volts in increments of 0.4 volts, and • 48-volt system: 42.0 to 5...

Installation 26 975-0004-01-02 Rev D 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 ...

Adjusting the C-Series Voltage Settings 975-0004-01-02 Rev D 27 Figure 2-14 Voltage Settings with R46 Resistor Clipped 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 ...

Installation 28 975-0004-01-02 Rev D Using a Digital Voltmeter to Adjust Voltage Settings A digital DC voltmeter (DVM) can be used to provide a more accurate setting of voltage parameters. Test points are provided at the mid-range on the scales for this purpose. The potentiometers are equipped with ...

Adjusting the C-Series Voltage Settings 975-0004-01-02 Rev D 29 For example for a 48-volt system: To set BULK voltage to 56.4 volts: 1. Point the BULK potentiometer to the mid-range position. 2. Adjust the potentiometer until the DVM displays 1.1 volts (1.1 x 4 [48 volt] = 4.4 + 52.0 = 56.4). Figure...

Installation 30 975-0004-01-02 Rev D Equalization Charging 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 e...

Equalization Charging 975-0004-01-02 Rev D 31 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. The equalizat...

Installation 32 975-0004-01-02 Rev D 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 th...

Temperature Compensation 975-0004-01-02 Rev D 33 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 contro...

Installation 34 975-0004-01-02 Rev D 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 Alkal...

Temperature Compensation 975-0004-01-02 Rev D 35 Table 2-2 Variances in Charging Voltage based on Battery Temperature Temperature (around the BTS) 12-volt units 24-volt units 48-volt units Celsius Fahrenheit Lead Acid (6 cells) NiCad (10 cells) Lead Acid (12 cells) NiCad (20 cells) Lead Acid (24 cel...

Installation 36 975-0004-01-02 Rev D If using a BTS, when the battery temperature drops below 77°F (25 °C), the regulation voltage setting automatically increases. When the temperature rises above 77°F (25 °C) the regulation battery voltage setting automatically decreases. Manual Battery Temperature...

Grounding 975-0004-01-02 Rev D 37 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 a...

Installation 38 975-0004-01-02 Rev D Wiring DC Terminal Connector Locations Terminal connectors for DC wiring are located on the lower edge of the circuit board. See Figure 2-21 . The common negatives can be reversed or wired with an appropriately sized single conductor to a more convenient location...

Wiring 975-0004-01-02 Rev D 39 Terminal Torque Requirements Once the wires have been installed, torque the terminals as follows. Be careful not to overtighten. • 20 inch-pounds for #14-10 AWG wire • 25 inch-pounds for #8 AWG wire • 35 inch-pounds for #6 AWG wire Wire Size and Over-current Protection...

Installation 40 975-0004-01-02 Rev D Minimum Recommended Wire Gauge The minimum recommended wire gauge is: • C35 and C40 Models: #8 AWG with a 75 °C (167 °F) insulation rating • C60 Models:#6 AWG, with a 90 °C (194 °F) insulation rating The terminals on the C-Series will accept up to #2 AWG (33.6 mm...

Wiring 975-0004-01-02 Rev D 41 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 powe...

Installation 42 975-0004-01-02 Rev D 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, ...

Wiring 975-0004-01-02 Rev D 43 Table 2-4 One-Way Wire Distance and Wire Size Maximum One-way Wire Distance for a < 3% Voltage drop 12 Vdc Application Shown For 24 Vdc Systems, Multiply distance by 2For 48 Vdc Systems, Multiply distance by 4 Distance in Feet (meters) Distance in Feet (Meters) a a....

Installation 44 975-0004-01-02 Rev D PV Charge Control Mode Wiring The procedure below is illustrated in Figure 2-23 . To connect the C-Series controller as a charge controller: 1. Connect the PV array’s positive (+) output to the PV array disconnect. 2. Route another (+) cable from the other end of...

Installation 46 975-0004-01-02 Rev D 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 conn...

Installation 48 975-0004-01-02 Rev D DC Load Control Mode Wiring The procedure below is illustrated in Figure 2-25 . To connect the C-Series controller as a DC load controller: 1. Connect a cable from the BAT POSITIVE terminal on the controller to a battery disconnect. 2. Connect the positive batter...

Wiring 975-0004-01-02 Rev D 49 Figure 2-25 Load Control Mode Wiring 4 2 1 5 3 Battery Positive (+) DC Load Positive (+) DC Load Negative (–) Battery Negative (–) Common Negatives

Installation 50 975-0004-01-02 Rev D 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...

Installing Optional Accessories 975-0004-01-02 Rev D 51 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 ...

Installation 52 975-0004-01-02 Rev D 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. Figure 2-28 Re-installing the C...

3 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 Indications (Green)” page 56 “Load Control Indications (Red)” page 58 “Err...

Operation 54 975-0004-01-02 Rev D Basic Operation The C-Series controller (all models) has one multicolor LED status indicator and one reset button. Figure 3-1 C-Series Status LED and Reset Button Location Multicolor LED indicator Reset Switch Reset Switch (on side of unit)

LED Status Indicator 975-0004-01-02 Rev D 55 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...

Operation 56 975-0004-01-02 Rev D Charge Control or Diversion Control Indications (Green) The flashing rate of the LED indicates the controller’s stage of operation and approximate battery voltage. • One to four flashes indicates the controller is in the Bulk stage. As the flashing rate increases, t...

LED Status Indicator 975-0004-01-02 Rev D 57 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 t...

Operation 58 975-0004-01-02 Rev D 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 mo...

LED Status Indicator 975-0004-01-02 Rev D 59 Error Mode Indication (Orange) The C-Series Multifunction DC Controller error modes include the following. • Over-temperature Condition - fast flash • Over-current Condition - fast flash • Low-Voltage Disconnect Condition (Load Control Mode) - slow flash ...

Operation 60 975-0004-01-02 Rev D 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...

Reset Switch 975-0004-01-02 Rev D 61 Reset Switch Use the Reset Switch on the side of the chassis for the following conditions. • To manually initiate battery equalization in Charge Control mode, press and hold the Reset Switch until the red and green LED start to flash. • To manually suspend batter...

4 Troubleshooting Chapter 4, “Troubleshooting” contains information about identifying and resolving possible problems with systems using a C-Series Multifunction DC Controller . For Information on: See: “PV Charge Control Troubleshooting” page 64 “Diversion Control Troubleshooting” page 66 “Load Con...

Troubleshooting 64 975-0004-01-02 Rev D 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 overc...

PV Charge Control Troubleshooting 975-0004-01-02 Rev D 65 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 measur...

Troubleshooting 66 975-0004-01-02 Rev D Diversion Control Troubleshooting The following table lists possible problems that may arise when using the C-Series Multifunction DC Controller as a Diversion Controller. Table 4-2 Diversion Control Problems Problem Possible Cause Solution Status LED Blinks O...

Diversion Control Troubleshooting 975-0004-01-02 Rev D 67 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 ...

Troubleshooting 68 975-0004-01-02 Rev D 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 poin...

A 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 Specifications” page 71 “Environmental Specifications” page 72

Specifications 70 975-0004-01-02 Rev D Electrical Specifications The following lists the electrical specifications for the C-Series controller s Models C35, C40, and C60. Table A-1 Electrical Specifications Model C35 C40 C60 Voltage Configuration 12 Vdc 24 Vdc 12 Vdc 24 Vdc 48 Vdc 12 Vdc 24 Vdc Maxi...

Features and Options Specifications 975-0004-01-02 Rev D 71 Features and Options Specifications The following lists the features and options specifications for the C-Series controller s Models C35, C40, and C60. Load Control Settings: System Voltage: Low Voltage ReconnectLow Voltage Disconnect 12 Vo...

Specifications 72 975-0004-01-02 Rev D Environmental Specifications The following lists the environmental specifications for the C-Series controller s Models C35, C40, and C60. Table A-3 Environmental Specifications Model C35 C40 C60 Enclosure Type Indoor, ventilated, powder-coated steel with 3/4...

B 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 74 975-0004-01-02 Rev D 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 setting...

Battery Types 975-0004-01-02 Rev D 75 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 l...

Batteries 76 975-0004-01-02 Rev D 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 ...

Equalization Charging 975-0004-01-02 Rev D 79 Equalization Setpoints (Non-Sealed Batteries Only) Table B-1 Typical Bulk and Float Setpoints for Batteries Battery Type Bulk Volts Float Volts Equalizing Charge Default Settings (knobs at nine o’clock position) 14.0 Vdc 13.5 Vdc Disabled (manual jumper)...

C Diversion Loads Appendix C, “Diversion Loads” provides additional information about Diversion Loads. For information on: See: “Diversion Load Types” page 82

Diversion Loads 82 975-0004-01-02 Rev D Diversion Load Types Several different types of diversion loads are available to the alternative energy market. These loads are designed to operate with the power output levels common to most diversion load controllers. The following are several available dive...

Diversion Load Types 975-0004-01-02 Rev D 83 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 ...

85 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 ...

Warranty and Product Information 86 975-0004-01-02 Rev D 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 we...

Return Material Authorization Policy 975-0004-01-02 Rev D 87 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,...

Warranty and Product Information 88 975-0004-01-02 Rev D 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 prod...

Information About Your System 975-0004-01-02 Rev D 89 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. If you need to contact Customer Service, please record the following...

A Accessories 12Automatic Equalization 32 B Battery Safety Information viiiBattery Temperature Compensation 6Battery Temperature Sensor 12, 51BULK charge voltage 22 C Charge Control or Diversion Control Mode Indications 59 Customer Service preparing to call 89 D Diversion Control Mode 8, 26 E EQ/LVR...

Xantrex Technology Inc. 1 800 670 0707 Tel toll free NA1 360 925 5097 Tel direct1 800 994 7828 Fax toll free NA1 360 925 5143 Fax [email protected] 975-0004-01-02 Printed in China