Xantrex Technology C40, C35, C60 owner manual Bulk Stage, Stage Battery Charging Process

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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 (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. 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 Voltage		Increasing Voltage	Constant Voltage	Reduced Voltage
0 volts
		Max Amps
DC Current		Constant Current	Reducing Current	Reduced Current
0 amps
Time
Figure 1-2	3-stage Battery Charging Process

975-0004-01-02 Rev D

5

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Contents Series Multifunction DC Controller Page Series Multifunction DC Controller Trademarks About XantrexDisclaimer Date and RevisionScope PurposeAudience OrganizationFollowing conventions are used in this guide Conventions UsedRelated Information Abbreviations and AcronymsPage General Safety Instructions Important Safety InstructionsViii Rev D Battery Safety InformationBattery Safety Information Page Contents Xii Rev D Specifications TroubleshootingOperation BatteriesDiversion Loads Warranty and Product InformationFigures Xvi Rev D Tables Xviii Introduction 1C-Series Multifunction DC Charge Controllers FeaturesLoad Control Mode Charge Control ModeOperating Modes Three-Stage Battery Charging Charge Control ModeBulk Stage Stage Battery Charging ProcessBattery Temperature Compensation Load Control ModeManual or Auto Equalization Charge Photovoltaic Charge Controller Controller FunctionsAutomatic PV Array Night Disconnect Diversion Controller4Diversion Controller Diversion LoadsLoad Controller Low Voltage Reconnect Low Voltage Disconnect6Decal Displaying Load Control Voltage Settings Optional AccessoriesInstallation Removing the Top Cover Pre-InstallationRemoving Knockouts 2C-Series Dimensions and Knockout Locations Not to Scale To mount the C-Series controller Mounting the Controller3Mounting the C-Series Multifunction DC Controller Jumper Settings Configuring the C-SeriesController5Circuit Board Components 1Factory Default Settings for C-Series ControllersVoltage Jumper Operating Mode Jumper8EQ/LVR Jumper and Reset Switch 9Bulk and Float Charge Potentiometers pots Adjusting the C-Series Voltage SettingsAdjusting the C-Series Voltage Settings 11Potentiometers with Decal for LVR and LVD Settings Setting Voltage Parameters for Load Control Mode12LVR and LVD Settings for Load Control Mode Setting Voltage Parameters for Alkaline Batteries Setting Voltage Parameters Diversion Control Mode14Voltage Settings with R46 Resistor Clipped To test and adjust the voltage setting using a DVM Using a Digital Voltmeter to Adjust Voltage SettingsTo set the Bulk voltage to 14.4 volts To set Bulk voltage to 28.2 voltsTo set Bulk voltage to 56.4 volts 15Test Points for Adjusting Voltage Using a DVMEqualization Charging 16Manual Equalization SettingsManual Equalization 17Front Panel LED and Reset Switch LocationAutomatic Equalization 18Auto Equalization SettingsTerminating the Equalization Process Temperature CompensationAutomatic Battery Temperature Compensation Temperature Compensation Based on Battery TypeLead-Acid Type Batteries 2Variances in Charging Voltage based on Battery Temperature Manual Battery Temperature Compensation 20Grounding the C-SeriesChassis GroundingDC Terminal Connector Locations WiringCurrent Rating Terminal Torque RequirementsSurge Protection Minimum Recommended Wire GaugeC35 and C40 Models C60 ModelsOver-current Protection 3Minimum Wire SizeMaximum One-way Distance and Wire Size Long-distance wire runsDistance in Feet meters 4One-Way Wire Distance and Wire SizeTo connect the C-Seriescontroller as a charge controller PV Charge Control Mode Wiring23PV Charge Control Mode Wiring To connect the C-Seriesas a diversion load controller Diversion Control Mode Wiring24Diversion Control Mode Wiring To connect the C-Series controller as a DC load controller DC Load Control Mode Wiring25Load Control Mode Wiring Installing a Digital Display Installing Optional AccessoriesTo install the BTS Installing the Battery Temperature SensorTo reinstall the faceplace on the C-Series controller Reinstalling the FaceplateOperation Basic Operation 1C-Series Status LED and Reset Button Location2C-Series Front Pa el Label LED Status IndicatorCharge Control or Diversion Control Indications Green 1Battery Voltage LED IndicatorsSolid Green Blinking GreenLoad Control Indications Red Equalization Mode Indication Red/greenBlinking Red Solid RedOver-temperature Condition Error Mode Indication OrangeOver-Current Condition Low-voltage Disconnect Condition Reconnecting to Loads3Reset Switch Reset SwitchPage 4Troubleshooting 1PV Charge Control Problems PV Charge Control TroubleshootingPV Charge Control Troubleshooting 2Diversion Control Problems Diversion Control TroubleshootingDiversion Control Troubleshooting 3Load Control Problems Load Control TroubleshootingASpecifications Table A-1Electrical Specifications Electrical SpecificationsTable A-2Features and Options Specifications Features and Options SpecificationsTable A-3Environmental Specifications Environmental SpecificationsBBatteries Maintenance-Free Batteries Battery TypesAutomotive Batteries Deep-Cycle BatteriesSealed Batteries NiCad and NiFe Batteries Battery SizingEqualization Charging Rev D Table B-1Typical Bulk and Float Setpoints for Batteries Equalization Setpoints Non-Sealed Batteries OnlyPage CDiversion Loads Diversion Load Types Power DissipationDiversion Load Types Page Warranty Warranty and Product InformationProduct DisclaimerExclusions Return Material Authorization PolicyOut of Warranty Service Return ProcedureSerial Number on DC end Purchased From Purchase Date Information About Your SystemPage Index Index Page Xantrex Technology Inc