Xantrex C35 Owner's Manual
C-series multifunction dc controller
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Summary of Contents for Xantrex C35
- Page 1 Smart choice for power C-Series Multifunction DC Controller Owner’s Manual www.xantrex.com...
- Page 3 C-Series Multifunction DC Controller Owner’s Guide...
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Page 4: Contact Information
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. -
Page 5: About This Guide
About This Purpose The purpose of this procedures for installing, operating, maintaining, and troubleshooting the Scope This Guide 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. - Page 6 About This Guide Chapter 2 contains information and procedures to install C-Series Multifunction DC Controller. Chapter 3 contains information about the operation of a C-Series Multifunction DC Controller. Chapter 4, “Troubleshooting” contains information about identifying and resolving possible problems with systems using a C-Series Multifunction DC Controller.
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Page 7: Abbreviations And Acronyms
Abbreviations and Acronyms CM/R Related Information You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com. 975-0004-01-02 Rev D Authorized Service Center Battery Temperature Sensor C-Series Meter C-Series Meter - Remote Direct Current... -
Page 9: General Safety Instructions
Important Safety Instructions WARNING This manual contains important safety instructions that should be followed during the installation and maintenance of this product. Be sure to read, understand, and save these safety instructions. General Safety Instructions • All electrical work must be done in accordance with local, national, and/or international electrical codes. -
Page 10: Battery Safety Information
Safety 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 when working with batteries. - Page 11 CAUTION: A battery can produce the following hazards to personal safety: • electrical shock, • burn from high-short-circuit current, and/or • fire or explosion from vented gasses. Observe proper precautions when working with or around batteries. 975-0004-01-02 Rev D Battery Safety Information...
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Page 13: Table Of Contents
Contents Important Safety Instructions 1 Introduction Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 Operating Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 Charge Control Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 Three-Stage Battery Charging - - - - - - - - - - - - - - - - - - - 4... - Page 14 Contents 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...
- Page 15 3 Operation Basic Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54 LED Status Indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55 Charge Control or Diversion Control Indications (Green) - - 56 Blinking Green - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 Solid Green - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57...
- Page 16 Contents Battery Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76 Equalization Charging- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77 Equalization Setpoints (Non-Sealed Batteries Only) - - - - - - 79 C Diversion Loads Diversion Load Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82...
- Page 17 Figures 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 - - - - - - - - - - - - - - - - - - - - - - - - 9 Figure 1-5...
- Page 18 Figures Figure 2-22 AWG Wire Gauge Reference Chart - - - - - - - - - - - - - 40 Figure 2-23 PV Charge Control Mode Wiring - - - - - - - - - - - - - - 45 Figure 2-24 Diversion Control Mode Wiring - - - - - - - - - - - - - - - 47 Figure 2-25 Load Control Mode Wiring - - - - - - - - - - - - - - - - - - 49 Figure 2-26 Installing a Digital Display - - - - - - - - - - - - - - - - - - - 50...
- Page 19 Tables 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...
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Page 21: Introduction
Introduction Chapter 1 C-Series Multifunction DC For information on: “Features” “Operating Modes” “Controller Functions” “Optional Accessories” describes features and functions of the Controller. See: page 2 page 3 page 7 page 12... -
Page 22: Features
Introduction Features The C35/C40/C60 (C-Series) controllers can be used with 12-volt, 24-volt, or 48-volt DC systems (depending upon model) as Charge Controller or a Load Controller. Figure 1-1 C-Series Multifunction DC Charge Controllers Numerous features are provided standard to maximize the performance of the system: •... -
Page 23: Operating Modes
• Meets National Electrical Code (NEC) and other international controller specifications. • The C35, C40 and C60 models are UL listed to the U.S. UL Standard 1741 (1st edition), and Canada (CSA-C22.2 No. 107.1-95). • 2-year limited warranty. -
Page 24: Charge Control Mode
Introduction Important: 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 batteries are charged by the DC source (solar, wind, or hydro). -
Page 25: Figure 1-2 3-Stage Battery Charging Process
Bulk Stage During this stage, the batteries are charged at the bulk voltage setting and maximum current output of the DC source. When the battery voltage reaches the bulk voltage setting, the controller activates the next stage (absorption). Absorption Stage During this stage, the voltage of the battery is held at the bulk voltage setting until an internal timer has accumulated one hour. -
Page 26: Battery Temperature Compensation
Introduction Battery Temperature Compensation The optional Battery Temperature Sensor (BTS) automatically adjusts the charging process of the controller. With the BTS installed, the 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. -
Page 27: Controller Functions
60 amps of continuous photovoltaic (PV) array current at 12 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. -
Page 28: Automatic Pv Array Night Disconnect
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). “Operating Mode Jumper”... -
Page 29: Diversion Loads
Figure 1-4 Diversion Controller Diversion Loads Diversion control requires a separate “dump” load to regulate the battery. This load must be able to absorb more power than the charging source is able to produce at its peak output, or the DC voltage will become unregulated. The dump load must be available for the diversion of power at all times. -
Page 30: Load Controller
Introduction Important: 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: 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. -
Page 31: Low Voltage Disconnect
or automatic reconnect when the controller. Do not use this decal if using the controller Low Voltage Disconnect When configured as a load controller, the will disconnect the load from the batteries when it reaches the LVD setting. There will be a 6-minute delay after the voltage drops below the Low Voltage Disconnect (LVD) setting before the controller actually disconnects the load. -
Page 32: Optional Accessories
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 • Display Meters: The CM faceplate or CM/R remote display provide a digital display for monitoring the C-Series attaches directly to the front of the... -
Page 33: Installation
Installation Chapter 2 C-Series Multifunction DC For information on: “Pre-Installation” “Mounting the Controller” “Configuring the C-Series Controller” “Adjusting the C-Series Voltage Settings” “Grounding” “Wiring” “Installing Optional Accessories” “Installing the Battery Temperature Sensor” contains information and procedures to install Controller. See: page 14 page 16 page 18... -
Page 34: Pre-Installation
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: standards. Installations of this equipment should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy (RE) System Installers. -
Page 35: Figure 2-2 C-Series Dimensions And Knockout Locations
It is also recommended to use bushings or conduits to protect the wiring from damage from rough edges in the knockout holes. Heatsink not included on C35 8" (203 mm) 2 ¼” (64 mm) This distance varies per model: C35 = 3/8"... -
Page 36: Mounting The Controller
Installation Mounting the Controller C-Series controller 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 installed in a rainproof enclosure to eliminate exposure to rain, mist or water-spray. - Page 37 WARNING: Explosion/Corrosion Hazard Do not locate the 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.
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Page 38: Configuring The C-Series Controller
Installation Configuring the Before making any wiring connections to the 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. -
Page 39: Figure 2-5 Circuit Board Components
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 Configuring the C-Series Controller C35, C40 and C60 12 volts DC Manual Equalization Charge Control NiCad Setting... -
Page 40: Operating Mode Jumper
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 C35 and C60... -
Page 41: Automatic/Manual Battery Equalization (Eq) And Low Voltage Reconnect (Lvr) Jumper
Automatic/Manual Battery Equalization (EQ) and Low Voltage Reconnect (LVR) Jumper Depending on the mode of operation chosen, this jumper enables: • automatic or manual battery equalization (Charge Control mode), or • automatic or manual reconnect in the event of low voltage event (Load Control mode). -
Page 42: Adjusting The C-Series Voltage Settings
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. -
Page 43: Control Mode
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 58.0 volts in increments of 0.8 volts. -
Page 44: Setting Voltage Parameters For Load Control Mode
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 controller scale calibration is altered from what is printed on the circuit board. -
Page 45: Figure 2-12 Lvr And Lvd Settings For Load Control Mode
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 50.0 volts in increments of 0.8 volts. -
Page 46: Setting Voltage Parameters Diversion Control Mode
Installation Setting Voltage Parameters Diversion Control Mode When the 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. Figure 2-10 on page 23 The unit will continue diverting excess current to the diversion load until the source voltage falls to or below the BULK setting. -
Page 47: Figure 2-14 Voltage Settings With R46 Resistor Clipped
17.0 16.6 16.8 16.4 16.2 16.0 15.8 15.6 15.0 15.4 15.2 16.1 16.3 16.5 15.9 15.7 15.5 15.3 15.1 14.5 14.9 14.7 12-Volt System Settings 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. -
Page 48: Using A Digital Voltmeter To Adjust Voltage Settings
Installation Using a Digital Voltmeter to Adjust Voltage Settings A digital DC voltmeter (DVM) can be used to provide a more accurate setting of voltage parameters. Test points are provided at the mid-range on the scales for this purpose. The potentiometers are equipped with removable knobs to prevent accidental mis-adjustments. -
Page 49: Figure 2-15 Test Points For Adjusting Voltage Using A Dvm
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). TEST POINTS for DVM (center legs of potentiometer) -
Page 50: Equalization Charging
Installation Equalization Charging CAUTION: Damage to Batteries Equalization should be done for standard electrolyte, vented batteries only. Sealed, GEL cell, or NiCad batteries should not be equalize-charged. Consult your battery supplier for details on equalize-charging for the battery type in your system. C-Series the equalization charging process. -
Page 51: Manual Equalization
Manual Equalization Manual equalization of the battery can be enabled by pressing the Reset Switch on the right side of 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) Figure 2-17 Front Panel LED and Reset Switch Location... -
Page 52: Automatic Equalization
Installation Automatic Equalization C-Series controller 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. -
Page 53: Terminating The Equalization Process
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. -
Page 54: Temperature Compensation Based On Battery Type
Installation Temperature Compensation Based on Battery Type C-Series controller temperature compensated voltage settings. The temperature compensated charging voltage is normally based on a Lead – Acid types of battery. If using Alkaline-type batteries, the R46 resistor on the circuit board inside the controller will have been clipped as shown in on page compensation charging voltage will be based on... -
Page 55: Table 2-2 Variances In Charging Voltage Based On Battery Temperature
Table 2-2 Variances in Charging Voltage based on Battery Temperature Temperature (around the BTS) Celsius Fahrenheit 975-0004-01-02 Rev D 12-volt units 24-volt units Lead Lead Acid NiCad Acid (6 cells) (10 cells) (12 cells) -1.05 -0.70 -2.10 -0.90 -0.60 -1.80 -0.75 -0.50 -1.50... -
Page 56: Manual Battery Temperature Compensation
Installation If using a BTS, when the battery temperature drops below 77°F (25 °C), the regulation voltage setting automatically increases. When the temperature rises above 77°F (25 °C) the regulation battery voltage setting automatically decreases. Manual Battery Temperature Compensation If no Battery Temperature Sensor (BTS) is installed and the batteries will be operating in very hot or very cold conditions, adjust the bulk and float settings to allow for the battery temperature. -
Page 57: Grounding
Grounding C-Series controller 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. -
Page 58: Wiring
Installation Wiring Important: standards. Installations of this equipment should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy (RE) System Installers. For a list of Xantrex Certified RE dealers, please visit our website at www.XantrexREdealers.com. WARNING: Shock Hazard Disconnect battery and PV sources before wiring. -
Page 59: Terminal Torque Requirements
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 Battery Positive (+) Figure 2-21 DC Connection Terminals... -
Page 60: Minimum Recommended Wire Gauge
Installation Minimum Recommended Wire Gauge The minimum recommended wire gauge is: • C35 and C40 Models: #8 AWG with a 75 °C (167 °F) insulation rating • C60 Models: #6 AWG, with a 90 °C (194 °F) insulation rating The terminals on the (33.6 mm... -
Page 61: Over-Current Protection
controller device on the input line of the the PV array and the controller. If the battery, is over 15 feet away from the controller, or if it is routed next to other wiring or sources of power, additional surge protection devices are recommended. Put the surge protection device for this scenario on the battery input line between the battery and the controller. -
Page 62: Long-Distance Wire Runs
Installation Long-distance wire runs If there is a significant distance between the PV array and the controller and/or the controller and the battery, larger wires can be used to reduce the voltage drop and improve performance. Refer to To use a larger size wire, use a splicer block (terminal block) intended for this purpose. -
Page 63: Table 2-4 One-Way Wire Distance And Wire Size
Table 2-4 One-Way Wire Distance and Wire Size Maximum One-way Wire Distance for a < 3% Voltage drop For 24 Vdc Systems, Multiply distance by 2 For 48 Vdc Systems, Multiply distance by 4 Distance in Feet (meters) Amps 8.8 ft. 14 ft. -
Page 64: Pv Charge Control Mode Wiring
Installation PV Charge Control Mode Wiring The procedure below is illustrated in WARNING: Shock Hazard PV arrays generate voltage whenever light strikes the surface of the array. Before connecting the disconnect the array to prevent any current from being generated. To connect the 1. -
Page 65: Figure 2-23 Pv Charge Control Mode Wiring
Wiring Common Battery Battery PV Array Negatives PV+ Array Positive (+) Negative (–) Negative (–) Positive (+) 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... -
Page 66: Diversion Control Mode Wiring
Installation Diversion Control Mode Wiring The procedure below is illustrated in When using the Controller, the DC load needs to be connected to the controller terminals marked as NEGATIVE To connect the 1. Connect your DC current source (PV, wind, hydro, etc.) directly to the RE disconnect. -
Page 67: Figure 2-24 Diversion Control Mode Wiring
Wiring Common Negatives Battery Diversion Load Battery Diversion Load Positive (+) Positive (+) Negative (–) Negative (–) Ensure the proper grounding is in place for the entire system. Figure 2-24 Diversion Control Mode Wiring 975-0004-01-02 Rev D... -
Page 68: Dc Load Control Mode Wiring
Installation DC Load Control Mode Wiring The procedure below is illustrated in To connect the C-Series controller as a DC load controller: 1. Connect a cable from the controller to a battery disconnect. 2. Connect the positive battery cable to the battery disconnect. -
Page 69: Figure 2-25 Load Control Mode Wiring
Wiring Common Negatives Battery DC Load Battery DC Load Positive (+) Positive (+) Negative (–) Negative (–) Figure 2-25 Load Control Mode Wiring 975-0004-01-02 Rev D... -
Page 70: Installing Optional Accessories
Installation Installing Optional Accessories The following sections describe how to install the optional accessories available for the 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. -
Page 71: Installing The Battery Temperature Sensor
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. -
Page 72: Reinstalling The Faceplate
Installation Reinstalling the Faceplate To reinstall the faceplace on the 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 CM Faceplate C-Series controller: Align these screw holes. -
Page 73: Operation
Operation Chapter 3 C-Series Multifunction DC For Information on: “Basic Operation” “LED Status Indicator” “Charge Control or Diversion Control Indications (Green)” “Load Control Indications (Red)” “Error Mode Indication (Orange)” “Reconnecting to Loads” contains information about the operation of a Controller. See: page 54 page 55... -
Page 74: Basic Operation
Operation Basic Operation C-Series controller status indicator and one reset button. Multicolor LED indicator Figure 3-1 C-Series Status LED and Reset Button Location (all models) has one multicolor LED Reset Switch 975-0004-01-02 Rev D Reset Switch (on side of unit) -
Page 75: 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. •... -
Page 76: Charge Control Or Diversion Control Indications (Green)
Operation Table 3-1 Battery Voltage LED Indicators Green LED (Charge/Diversion Mode) Battery at FLOAT Setting Battery at BULK Setting BULK Setting Minus (–) 0.25 Vdc 0.50 Vdc 0.50 Vdc 1.00 Vdc 0.75 Vdc 1.50 Vdc > 0.75 > 1.50 below Bulk below Bulk 12 volts 24 volts... -
Page 77: Blinking Green
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 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). -
Page 78: Equalization Mode Indication (Red/Green)
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. -
Page 79: Error Mode Indication (Orange)
Error Mode Indication (Orange) C-Series Multifunction DC Controller include the following. • Over-temperature Condition - fast flash • Over-current Condition - fast flash • Low-Voltage Disconnect Condition (Load Control Mode) - slow flash Over-temperature Condition The temperature of the controller’s transistors is continuously monitored. -
Page 80: Low-Voltage Disconnect Condition
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”... -
Page 81: Reset Switch
Important: mode; never in Charge or Diversion mode (unless it is reversed upon reinstallation). Reset Switch Use the Reset Switch on the side of the chassis for the following conditions. • To manually initiate battery equalization in Charge Control mode, press and hold the Reset Switch until the red and green LED start to flash. -
Page 83: Troubleshooting
Troubleshooting Chapter 4, “Troubleshooting” about identifying and resolving possible problems with systems using a For Information on: “PV Charge Control Troubleshooting” “Diversion Control Troubleshooting” “Load Control Troubleshooting” contains information C-Series Multifunction DC Controller. See: page 64 page 66 page 68... -
Page 84: Pv Charge Control Troubleshooting
Troubleshooting PV Charge Control Troubleshooting The following table lists possible problems that may arise when using the PV Charge Controller. Table 4-1 PV Charge Control Problems Problem Controller is overcharging battery (verified by measured current through the controller). Controller is locking up. PV positive and Status LED Blinks Orange after switching on array breaker. - Page 85 Table 4-1 PV Charge Control Problems Problem Current uneven between multiple controllers. Status LED blinks red while mode jumper is in “charge control” but still regulates normally. Battery voltage is exceeding Bulk and Float settings in cold weather and not reaching settings in hot weather.
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Page 86: Diversion Control Troubleshooting
Troubleshooting Diversion Control Troubleshooting The following table lists possible problems that may arise when using the Diversion Controller. Table 4-2 Diversion Control Problems Problem Status LED Blinks Orange after switching on diversion load breaker or when diversion begins (Bulk or Float settings reached). - Page 87 Table 4-2 Diversion Control Problems Problem Diversion load operates while a generator (fuel powered) is running. Diversion load operates immediately at full power when load breaker is turned on. 975-0004-01-02 Rev D Diversion Control Troubleshooting Possible Cause Bulk Voltage setting on diversion controller is set too close to other charger settings.
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Page 88: Load Control Troubleshooting
Troubleshooting Load Control Troubleshooting The following table lists possible problems that may arise when using the Load Controller. Table 4-3 Load Control Problems Problem Load disconnects at different point than set for. Status LED Blinks Orange after switching on the load breaker. C-Series Multifunction DC Controller Possible Cause A. -
Page 89: Specifications
Specifications Appendix A, “Specifications” for the For information on: “Electrical Specifications” “Features and Options Specifications” “Environmental Specifications” C-Series Multifunction DC provide the specifications Controller. See: page 70 page 71 page 72... -
Page 90: Electrical Specifications
12 Volt System: Float 14.5 - 16.5 Vdc Bulk 15.0 - 17.0 Vdc EQ = not recommended controllers Models C35, C40, and C60. 24 Vdc 12 Vdc 24 Vdc 48 Vdc 55 Vdc 125 Vdc 125 Vdc 125 Vdc 55 Vdc... -
Page 91: Features And Options Specifications
24 Volt System: LVR 24.0 to 28.0 Vdc LVD 21.0 to 25.0 Vdc controllers Models C35, C40, and C60. Multi color LED indicates the operating/battery voltage status. User selectable manual or automatic reconnection - includes warning flash before disconnect and 6 minutes “grace” period. -
Page 92: Environmental Specifications
Weight (Shipping) 3.0 lbs (1.4 kg) *Specifications at 25°C Specifications subject to change without notice controllers Models C35, C40, and C60. 10" x 5" x 2.5" (25.4 cm x 1.7 cm x 6.35 cm) 3.0 lbs (1.4 kg) 3.5 lbs (1.6 g) 3.0 lbs (1.4 kg) - Page 93 Batteries Appendix B, “Batteries” For information on: “Battery Types” “Battery Sizing” “Equalization Charging” describes types of batteries. See: page 74 page 76 page 77...
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Page 94: Battery Types
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 supplier of the batteries. -
Page 95: Sealed Batteries
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. -
Page 96: Nicad And Nife Batteries
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”... -
Page 97: 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. - Page 98 Batteries CAUTION: Damage to Batteries Equalization should be done only on vented (not sealed or maintenance-free) lead-acid, liquid-electrolyte batteries. The battery manufacturer should be consulted before attempting to equalize any other battery type. Add clean, distilled water to the battery following the equalization process. CAUTION: Damage to Loads DC loads may need to be disconnected by turning off circuit breakers or removing fuses before equalization to prevent damage...
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Page 99: Equalization Setpoints (Non-Sealed Batteries Only)
Equalization Setpoints (Non-Sealed Batteries Only) Table B-1 Typical Bulk and Float Setpoints for Batteries Battery Type Default Settings (knobs at nine o’clock position) Sealed Gel Lead Acid Battery AGM Lead Acid Battery Maintenance-Free RV/Marine Deep-Cycle, Liquid Electrolyte Lead Antimony Battery NiCad or NiFe Alkaline Battery Values shown are for 12-volt systems. -
Page 101: Diversion Loads
Diversion Loads Appendix C, “Diversion Loads” information about Diversion Loads. For information on: “Diversion Load Types” provides additional See: page 82... -
Page 102: Diversion Load Types
Diversion Loads Diversion Load Types Several different types of diversion loads are available to the alternative energy market. These loads are designed to operate with the power output levels common to most diversion load controllers. The following are several available diversion loads which may be used successfully for heating water or air. - Page 103 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.
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Page 105: Warranty And Product Information
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 Series Multifunction DC of purchase at the point of sale to you, the original end user customer. You require proof of purchase to make warranty claims. -
Page 106: Disclaimer
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. -
Page 107: 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... -
Page 108: Return Procedure
This warranty will not apply where the product is damaged due to improper packaging. 2. Include the following: • The RMA number supplied by Xantrex Technology, Inc. clearly marked on the outside of the box. • A return address where the unit can be shipped. Post office boxes are not acceptable. -
Page 109: Information About Your System
Information About Your System As soon as you open your following information and be sure to keep your proof of purchase. ❐ Serial Number (on DC end) ❐ Purchased From ❐ Purchase Date If you need to contact Customer Service, please record the following details before calling. -
Page 111: Index
Index Accessories 12 Automatic Equalization 32 Battery Safety Information viii Battery Temperature Compensation 6 Battery Temperature Sensor 12, 51 BULK charge voltage 22 Charge Control or Diversion Control Mode Indications 59 Customer Service preparing to call 89 Diversion Control Mode 8, 26 EQ/LVR Jumper 21 Equalization Charging 30 Equalization Mode Indication 57... - Page 112 Index Reset Switch 59 Safety Instructions vii serial number 89 Test Points for Voltage Settings 28 Torque Requirements 39 Troublshooting 64 Voltage Jumper 20 warranty out of warranty service 88 terms and conditions 85 Wire Size 39 Wiring 38 Xantrex web site v 975-0004-01-02 Rev D...
- Page 114 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...
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Questions and answers
Remote panel goes blank when load applied.