Trace Engineering C40 User Manual

C40
Charge-Diversion
& Load Controller
Introducing the C40
The C40 controller is the finest large-system
controller available. The C40 can be used with
12, 24, or 48-volt DC systems as a PV charge
controller, a DC diversion controller, or a DC
load controller (low voltage disconnect). These
capabilities make the C40 the only DC controller
you’ll need! Numerous standard features are
provided to maximize the performance of the
system:
Silent, solid-state Pulse Width Modulated
(PWM) charging process with three-stage
control, temperature compensation, and
manual or automatic equalization.
Maximizes system performance and
increases battery life.
Meets National Electrical Code (NEC) and
other international controller specifications.
Certified by ETL for the U.S. (UL Standard
1741 (draft), and Canada (CSA-C22.2 No.
14-M91 SEP 91)
Electronic overload and short circuit
protection with automatic and manual reset
capability increases the reliability of
unattended systems by eliminating blown
fuses and tripped circuit breakers
Field adjustment of charge setpoints is
provided by rotary controls with removable
knobs, reducing the potential for setpoint
tampering. Calibrated scales and test points
allow precise adjustments of settings
Optional external battery temperature compensation sensor (BTS) for automatic
adjustment of charge setpoints (required by UL draft standard 1741 and strongly
recommended for sealed batteries)
Over-temperature protection of the electronic circuitry (by reducing the charge rate)
improves the reliability of the C40 when used in environments over 113 F / 45 C.
Indoor-type, powder-coated enclosure for wall mounting
Multi-color status LED with matching color label for mode/status indication
Optional LCD meter for remote or direct mounting on the C40. May be mounted up to
1000 feet away
2 year limited warranty
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Introducing the C40
1
Copyright Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 2680 Rev. C
5916 195 Street, NE Fax (360) 435-2229 November 4, 1998
Arlington, WA 98223 USA www.traceengineering.com Page
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Trace Engineering C40 Specifications

General

Brand	Trace Engineering
Model	C40
Category	Controller
Language	English

Summary

Important Safety Instructions

General Precautions

General safety advice for operating the C40 controller, including electrical hazards.

Personal Precautions

Safety advice related to personal contact, battery acid, and electrical safety.

Operating Modes of the C40 Controller

Photovoltaic Charge Control Mode

Details operation in PV charge control mode, including status indications.

Diversion Control Mode

Explains operation in DC diversion control mode, including excess power diversion.

DC Load Control Mode

Details operation in DC load control mode, including low voltage disconnect.

Key Features of the C40

Over Temperature Protection

Explains protection against excessive heat for the controller's transistors.

Electronic Overcurrent Protection

Details protection against overcurrent and short circuits with auto-reset.

Battery Temperature Compensation

Explains automatic adjustment of charge setpoints based on battery temperature.

LED Status Indicator Guide

Charge/Diversion Control Mode Indications

Describes LED status for charge and diversion control modes.

Load Control Mode Indications

Explains LED status for load control mode (red, orange).

Equalization Process Indication

Explains LED status when battery equalization is in process.

Installation and Wiring

Mounting the Controller

Instructions for mounting the C40 controller securely on a wall.

Wiring Guidelines and Cabling

General wiring best practices and specific cabling for different modes.

Configuring the C40

Setting Voltage Parameters

How to set voltage parameters using jumpers on the circuit board.

Operating Mode Selection

How to select the operating mode (Charge, Diversion, Load Control).

Adjusting C40 Voltages

Setting Charge Voltage Parameters

Adjusting Bulk and Float charge voltages via potentiometers.

Using Testpoints for Voltage Settings

Using test points with a voltmeter for accurate voltage adjustment.

Equalization Process

Manual Equalization

How to initiate and manage manual battery equalization.

Automatic Equalization

How to enable and manage automatic equalization cycles.

Temperature Compensation Settings

Battery Temperature Compensation

Adjusting settings for optimal battery temperature compensation.

Setting Load Control Voltages (LVR/LVD)

Setting low voltage reconnect (LVR) and disconnect (LVD) levels.

Setting Diversion Control Voltage (HVD)

Setting high voltage diversion (HVD) points for diversion mode.

C40 Digital Volt Meter Displays

Display Installation and Mounting

Instructions for installing and mounting the optional DVM/C40 displays.

Three Stage Battery Charging Process

Battery Setpoints and Equalization

Typical BULK and FLOAT Setpoints

Table of default and recommended bulk and float setpoints for various batteries.

Equalization for Non-Sealed Batteries

Explains the process and considerations for equalizing non-sealed batteries.

Battery Types and Sizing

Battery Types and Usage

Guidance on using maintenance-free, deep cycle, and sealed batteries.

NiCad, NiFe Batteries, and Battery Sizing

NiCad and NiFe Battery Compatibility

Compatibility and settings adjustments for NiCad and NiFe batteries.

Battery Sizing Guidelines

Guidance on computing and selecting the appropriate battery bank size.

Diversion Loads Explained

Explanation of diversion loads and their purpose in power systems.

Selecting a Diversion Load

Warranty Service Procedure

Limited 2 Year Warranty

C40 Specifications and Features