Xantrex Technology C40, C35, C60 owner manual Over-current Protection, 3Minimum Wire Size

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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 protection 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 2-3for a listing of the minimum wire size and over-current device ratings to be used for each model.

As a minimum, a 60-ampDC-ratedcurrent-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 2-3for the correct ratings of the fuse and circuit breaker.

Table 2-3Minimum Wire Size

Controller	Minimum Wire Size	Over-Current Device Rating

C35	#8 AWG	45 amps

C40	#8 AWG	50 amps

C60a	#6 AWG (90 °C/194 °F wire)	60 amps (listed 100% duty)
C60	#4 AWGb (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

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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 Grounding DC 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