Xantrex Technology C40, C35, C60 owner manual Equalization Charging

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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 the 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

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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 Types Automotive 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