Trace Engineering C40 User Manual

5
diversion load to redirect the excess power generated instead of allowing it to flow into the
battery. This prevents damage to the charging source from an over-speed condition which
could occur if the charging source is suddenly disconnected from all loads - as series relay
regulators do. Consult your dealer for load and regulator size recommendations.
When the C40 operates as a diversion regulator, it provides three-stage regulation of
battery voltage, with temperature compensation and automatic or manual equalization.
See the section for more information on this process.
Diversion mode requires a separate load “dump” to regulate the battery. This load must be
able to absorb more power than the charging source is able to produce at its peak output,
or the DC voltage will become unregulated. The dump load must be available for the
diversion of power at all times. Resistive-type heating elements are the best diversion
loads. Special direct current water heating elements are available. Light bulbs and motors
are not recommended as diversion loads because they are unreliable.
When used in diversion mode, ensure that the operating mode jumpers are on the charge
control pins. See the section of this booklet.
Current draw of the diversion load is very important. Problems may arise from operating
with a load that is too small or too large. A diversion load that is too small will not be able to
absorb all the excess power from the current source once the batteries are full.
Diversion loads in excess of 63 amps are capable of absorbing more power than the C40 is
designed to handle, resulting in an over-current shut down. During this time, the unit will
not regulate electrical flow in the system, and battery damage may result.
A diversion load that draws about 50 amps when connected to the battery is usually
suitable for use with the C40. The load should be sized about 25% larger than the charging
source’s maximum output capability.
The C40 can also operate as a 40-amp load control (also called a low voltage disconnect)
to manage the discharging of the battery. A load controller prevents damage to the battery
from over-discharge during periods of poor weather or excessive loads.
When used in load control mode, ensure that the operating mode jumpers are on the load
control pins. See section of this booklet.
The controller delays disconnecting the DC loads for 10 minutes after the voltage drops
below the low voltage disconnect (LVD) setting. Loads are either automatically or manually
reconnected when battery voltage exceeds the low-voltage reconnect (LVR) setting for 10
minutes. The EQUALIZE jumper determines manual or automatic reconnect when the C40
is used as a load controller.
When used as a DC load controller, the settings of the
LVR and LVD are controlled by two rotary knobs on the
circuit board. The scale on the adjustment pots differ
from the scale used for other functions. A decal with
the corrected adjustment scale is included with the C40
and shown at right. Place this scale over the pots
when using the C40 as a load controller. Do not
temperature-compensate these settings. Do not install
the optional battery temperature compensation sensor.
Three-stage Battery Charging
User Configuration Options
Configuring the C40
DC Load Control Mode
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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DC LOADDC LOAD
Battery
C40
controller
C40
controller
Battery
C40
controller
C40
controller
Diversion
‘dump’ load
Diversion
‘dump’
load
PV, HYDRO,
or WIND
PV, HYDRO,
or
WIND

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