Xantrex Complete Charge Controller Supplemental Owner s Manual Rev 1.0 Copyright 2012 1
Table of Contents Introduction 3 Main Components of the Xantrex Complete Charge Controller 3 Mounting the Xantrex Complete Charge Controller...4 Connecting the Wind Turbine to the Xantrex Complete Charge Controller 4 Setting the Voltage and Operating Mode Jumpers for the Xantrex C- Series Charge Controller 5 Adjusting the Voltage Settings of the Xantrex C- Series Charge Controller 5 Grounding the Xantrex Complete Charge Controller 5 Wiring the Xantrex Complete Charge Controller to the Renewable Energy (RE) System 5-6 Trouble Shooting the Xantrex Complete Charge Controller 6 2
Introduction Thank you for your purchase of the Windy Nation s Xantrex Complete Charge Controller. This Supplemental Owner s Manual is to be used as a supplemental guide to the Xantrex C- Series Charge Controller Owner Manual which is also included with your purchase. This supplemental manual in no way replaces the instructions in the Xantrex C- Series Charge Controller Owner s Manual. Before you begin to install Windy Nation s Xantrex Complete Charge Controller, you must completely read and understand the Xantrex C- Series Charge Controller Owner s Manual. Failure to read and understand the Xantrex C- Series Charge Controller Owner s Manual could result in property damage, serious injury and death. Main Components of the Xantrex Complete Charge Controller The Xantrex Complete Charge Controller consists of four main components: 1. The Xantrex C- Series Charge Controller (C35, C40 or C60): The Xantrex C- Series Charge Controller serves the purpose of monitoring the voltage of the battery bank. The charge controller regulates when power should be diverted to the dump loads to prevent overcharging of the battery bank. 2. An 80 amp 3- phase bridge rectifier: The 80 amp 3- phase bridge rectifier converts the 3- phase AC electricity of the wind turbine or renewable energy source to DC electricity. 3. Wire wound resistors (dump loads or diversion loads): The wire wound resistors act as dump loads and consume power from the battery bank to prevent the battery bank from being overcharged by the renewable energy source(s) (e.g. wind turbine, hydro, and solar). 4. Electrical wire: The electrical wire is used to make electrical connections between the charge controller, dump load(s), 3- phase bridge rectifier, and battery bank. Figure 1: Main components of Xantrex Complete Charge Controller. 3
Mounting the Xantrex Complete Charge Controller Use the four mounting holes at the base of the Xantrex Complete Charge Controller to mount the unit to a wall. The controller is designed for indoor mounting. Care should be taken in selecting a location and when mounting the enclosure. Avoid mounting it in direct sun light to prevent heating of the enclosure. The enclosure should be mounted vertically on a wall. In outdoor installations, the C- Series controller must be installed in a rainproof enclosure to eliminate exposure to rain, mist or water- spray. Connecting the Wind Turbine to the Xantrex Complete Charge Controller The three AC wires from the 3- phase AC wind turbine or renewable energy source need to be connected to the three AC terminals on the 3- phase AC bridge rectifier. Depending on (a) the length of the wire run between the wind turbine and the Xantrex Complete Charge Controller and (b) the power that the wind turbine produces, the three wires traveling from the wind turbine to the 3- phase bridge rectifier should be 8, 10 or 12 AWG stranded, outdoor rated wire. There is one unused cable gland on the face of the Xantrex Complete Charge Controller which is to be used to run these three wires into the enclosure. See photo and instructions below in Figure 2. Figure 2: Run the three AC wires coming from the wind turbine or renewable energy source (yellow wires) through the unused cable gland. Then connect these three wires to the three empty terminals on the 3- phase bridge rectifier. Make sure the your firmly tighten the cable gland after you have installed the three wires. 4
Setting the Voltage and Operating Mode Jumpers for the Xantrex C- Series Charge Controller Windy Nation configured the Voltage Jumper for the Xantrex C- Series Charge Controller at the factory. (e.g. 12 volt Xantrex Complete Charge Controllers have been set for 12 volt battery bank operation, 24 volt Xantrex Complete Charge Controllers have been set for 24 volt battery bank operation, and 48 volt Xantrex Complete Charge Controllers have been set for 48 volt battery bank operation.) WindyNation has also configured the Operating Mode Jumper at the factory. It has been set to Charge Control Mode Jumper which is the appropriate setting for operating the controller in Diversion Mode. Refer to page 20 of the Xantrex C- Series Owner s Manual for an explanation of how the Xantrex C- Series Voltage and Operating Mode Jumpers are configured to operate correctly. Adjusting the Voltage Settings of the Xantrex C- Series Charge Controller WindyNation has NOT set the bulk and float voltage trip points on the Xantrex C- Series Charge Controller. The reason this is NOT done by Windy Nation is because different battery types (e.g. automotive batteries, maintenance free batteries, deep cycle batteries, sealed batteries, etc.) require different charging /discharging voltage levels. Refer to pages 74-76 of the Xantrex C- Series Owner s Manual and contact the company that sold you the batteries or the manufacturer of the batteries to find out the appropriate voltage settings (bulk and float) for your particular batteries. Once you determine the appropriate charging (bulk and float) voltage settings for your batteries, refer to pages 4-5 and pages 22-29 in the Xantrex Owner s Manual for directions on how to set the bulk and float voltage settings on the Xantrex C- Series Charge Controller. Grounding the Xantrex Complete Charge Controller Refer to page 37 of the Xantrex Owner s Manual for instructions on how to properly ground the Xantrex C- Series Charge Controller. Wiring the Xantrex Complete Charge Controller to the Renewable Energy (RE) System For detailed instructions on wiring the Xantrex Charge Controller, refer to pages 38-43 and 46-47. The Windy Nation Xantrex Complete Charge Controller has been wired in Diversion Mode at the factory. Refer to pages 46-47 of the Xantrex Owner s Manual for a detailed description of the Diversion Mode wiring schematics. After reviewing pages 46-47 of the Xantrex Owner s Manual, you will see that there are additional wiring steps that must be completed to safely and properly connect the Xantrex Complete Charge Controller to your RE system. These steps are listed below and can be referred to on pages 46-47 of the Xantrex C- Series Owner s Manual: 5
1. Connect your DC current source (PV, wind, hydro, etc.) directly to the RE disconnect. This is the red wire marked 1 in Figure 3 below. 2. Connect another cable from the other side of the RE disconnect to the battery positive terminal. 3. Run a negative wire from the DC current source (PV, wind, hydro, etc.) to the battery negative terminal. This is the black wire marked 3 in Figure 3 below. 4. Connect a cable from the Xantrex controller terminal marked BAT POS to the battery disconnect. This is the red wire marked 4 in Figure 3 below. 5. Connect a cable from the battery disconnect to the positive terminal of the battery. 6. Connect a cable from the negative battery terminal to one of the terminals marked COMMON NEGATIVES on the controller s circuit board. This is the black wire marked 6 in Figure 3 below. 7. Connect a cable from the controller s other terminal marked COMMON NEGATIVES to the negative terminal of your DC diversion load. This is the black wire marked 7 in Figure 3 below. 8. Connect a cable from the controller s terminal marked PV+/LOAD+ to the positive terminal of the DC diversion load. This is the red wire marked 8 in Figure 3 below. Figure 3: Labeled wires inside the Xantrex Complete Charge Controller Trouble Shooting the Xantrex Complete Charge Controller Refer to pages 66-67 of the Xantrex C- Series Owner s Manual for trouble shooting solutions to common set- up and operating issues. 6