WINDY NATION TrakMax 30L User manual

TrakMax 30L User Manual
Revision 1.0
windynation
TrakMax 30L
MPPT Solar Charge Controller
CHC-TRMX-30
User’s Manual
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TrakMax 30L User Manual
Revision 1.0
Table of Contents
1Introduction ..................................................................................................................................................3
1.1 Safety ...................................................................................................................................................... 3
1.2 Definitions................................................................................................................................................3
2Product Overview.........................................................................................................................................4
2.1 Features .................................................................................................................................................. 4
2.2 Specifications .......................................................................................................................................... 5
2.2.1 Electrical Specifications.......................................................................................................................5
2.2.2 Physical Specifications........................................................................................................................ 6
2.2.3 Regulatory Information........................................................................................................................6
3Installation....................................................................................................................................................6
3.1 Electrostatic (ESD) Precautions..............................................................................................................7
3.2 Mounting..................................................................................................................................................7
3.3 Grounding................................................................................................................................................8
3.4 Connections.............................................................................................................................................8
3.5 Overcurrent Protection ..........................................................................................................................11
3.6 Overvoltage – Reverse Polarity Protection...........................................................................................11
3.7 Parallel Connection ...............................................................................................................................11
3.8 Temperature Sensors (Optional)...........................................................................................................11
3.8.1 Temperature Compensation..............................................................................................................12
3.8.2 Battery Temperature Sensor – BTS (BAT) .......................................................................................12
3.8.3 Environment Temperature Sensor (ENV) .........................................................................................13
3.9 Remote Monitor (Optional)....................................................................................................................14
3.9.1 Communication Cable.......................................................................................................................15
3.9.2 Connections.......................................................................................................................................15
3.9.3 Mounting............................................................................................................................................15
4Operation ...................................................................................................................................................16
4.1 Maximum Power Point Tracking (MPPT)..............................................................................................16
4.1.1 How MPPT Works.............................................................................................................................17
4.2 Power ....................................................................................................................................................17
4.3 LED Modes............................................................................................................................................17
4.4 Button Definitions ..................................................................................................................................18
4.5 LCD Graphic Indicators.........................................................................................................................18
4.6 LCD Interface Cycle ..............................................................................................................................19
4.7 Interface Definitions...............................................................................................................................19
4.7.1 PV / Solar Input Interface (Main)....................................................................................................... 19
4.7.2 Battery Interface – Charge Limit Setting ...........................................................................................19
4.7.3 Load Interface....................................................................................................................................20
4.7.4 Battery Capacity Interface.................................................................................................................20
4.7.5 Battery Temperature Compensation Interface..................................................................................20
4.7.6 Battery Type Interface....................................................................................................................... 21
4.8 Charge Mode.........................................................................................................................................22
4.8.1 Three Stage Charge..........................................................................................................................22
4.9 DC Load Control....................................................................................................................................22
4.9.1 Low Voltage Disconnect....................................................................................................................23
4.9.2 Low Voltage Reconnect ....................................................................................................................23
5Error Conditions.........................................................................................................................................23
6Troubleshooting and Support.....................................................................................................................24
6.1 Care.......................................................................................................................................................24
6.2 Troubleshooting.....................................................................................................................................24
6.3 Fuse Replacement ................................................................................................................................25
6.4 Support.................................................................................................................................................. 26
6.5 Limited Warranty ...................................................................................................................................26
6.6 Restrictions............................................................................................................................................26
6.7 Warranty Claims & Return Procedures.................................................................................................26
6.8 Disclaimer..............................................................................................................................................27
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6.9 Limitation of Liability..............................................................................................................................27
7Application..................................................................................................................................................28
7.1 Batteries ................................................................................................................................................ 28
7.1.1 Automotive Batteries .........................................................................................................................28
7.1.2 Maintenance-Free Batteries..............................................................................................................28
7.1.3 Deep-Cycle Batteries.........................................................................................................................28
7.1.4 Sealed Batteries................................................................................................................................28
7.1.5 Battery Sizing ....................................................................................................................................28
7.1.6 Equalization Charging .......................................................................................................................28
7.2 Wire Gauge Reference..........................................................................................................................29
1 INTRODUCTION
Thank you for purchasing the TrakMax 30L, another quality product from Windy Nation. This manual is intended
for anyone who needs to install and operate the solar charge controller.
The manual will provide safety guidelines, detailed planning, and procedures for installing and setting up the
solar charge controller, as well as information about operating and troubleshooting the unit.
The manual will not provide details about any of the connected equipment to the controller (eg: PV panels,
batteries, etc.). Information concerning any connected equipment should be available from the equipment
manufacturer.
1.1 SAFETY
Windy Nation Inc. (“Windy Nation”) is not assembling the wind unit, installing the solar system, or any other
product offered by Windy Nation. Windy Nation, and its directors, officers, and employees disclaim, and by
purchasing a Windy Nation wind or solar powered product you accept all liability and responsibility for damage
to property, injury, or death arising out of or related to the use or misuse of any product offered by Windy Nation.
Installation and servicing should be referred to qualified service personnel.
Remove all sources of power, photovoltaic and battery before servicing or installing.
During operation, the controller can be very hot to the touch.
Battery Safety
Warning: Batteries can produce explosive gasses; observe extreme caution.
Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
NEVER smoke or allow a spark or flame in the vicinity of the battery.
Be cautious of metal items such as jewelry and tools to reduce risk of short circuit.
Never charge a frozen battery.
Be sure battery is mounted in a well-ventilated compartment.
Purge excessive gas from the battery cells by filling each cell with distilled water until battery acid
reaches level specified by battery manufacturer. For batteries without cell caps, carefully follow
manufacturers charging instructions.
1.2 DEFINITIONS
•BTS Battery Temperature Sensor
•DC Direct Current
•LED Light Emitting Diode
•LVD Low Voltage Disconnect
•LVR Low Voltage Reconnect
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•B.SELECT Battery Type Selector
•BAT Battery
•CHG.MODE Charge Mode
•PV Photovoltaic
•MPPT Maximum Power Point Tracking
•PWM Pulse Width Modulation
2 PRODUCT OVERVIEW
The TrakMax solar charge controller is a 30 amp 12/24/48 Volt Maximum Power Point Tracking (MPPT)
photovoltaic (PV) battery charge controller. Through the use of MPPT technology, TrakMax can increase charge
current up to 30% or more compared to conventional solar charge controllers. TrakMax’s sophisticated three
stage charge control system can be configured to optimize charge parameters to precise battery requirements.
The unit is fully protected against voltage transients, over temperature, over current, reverse battery, and
reverse PV connections. An automatic current limit feature allows use of the full 30 amp capability without
worrying about overload or unnecessary fuse blows from excessive current, voltage, or amp-hour based load
control.
Series pass Pulse Width Modulation (PWM) charge voltage control combined with a multistage charge control
algorithm leads to superior charging and enhanced battery performance. The filtered PWM power control
system uses highly efficient and reliable power MOSFET transistors. The MOSFET’s are turned on and off at
high frequency to precisely control the charge voltage and the MPPT function.
Fully automatic temperature compensation of charge voltage is available to further improve charge control and
battery performance. The optional battery temperature sensor (purchased separately) is built for long term
reliability. The sensor element is environmentally sealed and encapsulated into a lug, which secures directly to
the battery. The TrakMax also includes an isolated RS485 port for connection to a remote monitor (purchased
separately).
For large system current applications (greater than 30 amps), multiple TrakMax units can be connected in
parallel.
2.1 FEATURES
Maximum efficiency of 97%
Wide PV Input Range (150V Voc)
DC Load Output Port (10A)
LCD and LED displays to indicate the status of charge
Lightning protection
Reverse current protection at night
Smart Error detection
Automatic overload protection
DSP controlled
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Natural Cooling
Silent, pulse width modulated (PWM), high efficiency operation
Dual Battery Temperature Compensation; (Optional Requires item CHC-BTSC-02)
Optional Remote Monitoring using (Requires item CHC-RMTR-01)
Configurable charging current (10A, 20A, 30A)
1
Fault LED
7
Battery Terminal
2
Charge LED
8
Temperature Sensor Connection*
3
PV LED
9
RS485 Remote Monitor Port*
4
Battery LED
10
PV Terminal Input
5
DC LOAD Terminal Output
11
Function Keys
6
Earth Ground Connection (unit side)
12
LCD Display
*Optional Equipment is required for operation (purchased separately)
2.2 SPECIFICATIONS
2.2.1 Electrical Specifications
Parameter
Value @25oC
Battery System Voltage
12 / 24 /48 VDC (auto-detect)
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Max Input Current
30 Amp
Max Battery Charging Current
10, 20, or 30 Amp
Load Current
10 Amp
Max PV Open Circuit Array Voltage
150VDC
Efficiency
97% @ full current
Typical Idle Consumption
< 160mA / 80mA / 40mA
Bulk Charge
14.4V(default)
Floating Charge
13.5V / 27V / 54V (default)
Over-voltage Indication
15.0 / 30.0 / 60.0 VDC
Over-voltage Recovery
14.8 / 29.6 / 59.2 VDC
Under-voltage Indication
8.5 / 17.0 / 34.0 VDC
Under-voltage Recovery
9.0 / 18.0 / 36.0 VDC
Temperature Compensation
0 - 10mV/oC (settable)
Load Control
ON / OFF
Low Voltage Reconnect
12.0 / 24.0 / 48.0 VDC
Low Voltage Disconnect
10.5 / 21.0 / 42.0 VDC
Altitude
Operating 6,560ft (2000m)
Enclosure Protection Class
IP20
Battery Temperature Sensor (BTS)
Optional sensor increases charging precision
Terminal Size (fine/single wire)
Maximum 6 AWG
NOTE: The optional battery temperature sensor automatically adjusts the charging process of the controller
according to the type of battery selected by the user. With the battery temperature sensor installed, the controller
will increase or decrease the battery charging voltage depending on the temperature of the battery to optimize the
charge to the battery and to maintain battery performance.
2.2.2 Physical Specifications
Parameter
Value
Dimension (H x W x D)
8.2” (210mm) x 6.7” (171mm) x 3.8” (98mm)
Unit Weight
4.4 lb. (2Kg)
Mounting
Vertical wall mount - indoor only
Cooling
Natural cooling
Operating Temperature
14oF to 122oF (-10oC to 50oC)
de-rating >104
o
F (40
o
C)
Storage Temperature
-25oC to 60oC
Operating Humidity
20 to 80% relative humidity (non-condensing)
Non-Operating Humidity
Greater than 95% relative humidity
38.7
o
C max wet bulb temperature with no damage
2.2.3 Regulatory Information
The TrakMax has safety approvals as follows:
•CE
•IEC 62109
FCC Requirements:
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1)
This device may not cause harmful interference, and (2) this device must accept any interference received,
including interference that may cause undesired operation.
3 INSTALLATION
Insure all terminating connections are clean and tight to prevent arcing and overheating.
Do not connect to a PV array capable of producing greater than 30 amps of short circuit current @ 25°C.
Do not connect to a PV array with an open circuit voltage (VOC) greater than 150VDC.
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Important: Installations should meet all local codes and standards. Installations of this equipment should only
be performed by skilled personnel such as licensed electricians and Certified Renewable Energy (RE) System
Installers.
Caution: Install the Solar charge controller in a dry, protected location away from sources of high temperature,
moisture, and vibration. Corrosion is not covered by the warranty.
3.1 ELECTROSTATIC (ESD) PRECAUTIONS
All electronic circuits may be damaged by static electricity. To minimize the likelihood of electrostatic damage,
discharge yourself by touching an electrical ground (e.g.: copper pipe) prior to handling the unit and avoid
touching components on the circuit boards. The risk of electrostatic damage is highest when relative humidity is
below 40%.
3.2 MOUNTING
The mounting location is important to the performance and operating life of the controller. The environment must
be dry and protected from water. If required, the controller may be installed in a ventilated enclosure with
sufficient airflow. Never install the TrakMax MPPT in a sealed enclosure. The controller may be mounted in an
enclosure with sealed batteries, but never with vented/flooded batteries. Battery fumes from vented batteries will
corrode and destroy the TrakMax MPPT circuits.
1) Place the TrakMax on a vertical surface protected from direct sun, high temperatures, and water. The
TrakMax requires at least 6 in (150 mm) of clearance above and below and at least 1 in (25 mm) on
each side for proper air flow as shown in figure below.
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2) Place the controller mounting bracket on the desired mounting surface and mark the location of each
keyhole (two per unit).
3) Secure the bracket using the two mounting screws (included).
a) If wall anchors (included) are to be used, a pilot hole will be required at the drill mark.
4) Remove the Mount-Lock screw on the TrakMax and carefully align the open ended keyholes on the
mounting bracket with the TrakMax Mounting screw heads and slide the TrakMax down into the
keyhole.
5) Replace the Mount-Lock screw on the TrakMax going first through the mounting bracket and into the
TrakMax and tighten for safety.
Warning: Explosion/Corrosion Hazard
Do not mount on flammable surface material (e.g.: wooden wall).
3.3 GROUNDING
The TrakMax is designed to work with grounded electrical systems. In the controller, ground is not connected to
the input terminal and output terminals.
Use a copper wire to connect the grounding terminal on the TrakMax enclosure to earth ground. The grounding
terminal is located on the left side of the enclosure as shown above.
Do not connect the system negative conductor to this terminal. NEC requires the use of an external ground fault
protection device (GFPD). The system electrical negative should be bonded through a GFPD to earth ground at
one (and only one) location. The grounding point may be located in the solar circuit or the battery circuit.
3.4 CONNECTIONS
WARNING: Shock Hazard
Solar PV array can produce open-circuit voltages in excess of 100 VDC when in sunlight. Verify that the solar
input breaker or disconnect has been opened (disconnected) before installing the system wires. Note that the
maximum PV open-circuit voltage for the TrakMax is 150 VDC. Do NOT attach the positive and negative PV
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cables to the TrakMax until the TrakMax has been connected to the positive and negative terminals of the
battery bank.
It is recommended to use a strain relief (bushings, connectors, clamp connectors, or wire glands) in each of the
three ¾ in openings.
The NEC requires that the wires carrying the system current never exceed 80% of the conductor’s current
rating. The table below provides the minimum size of copper wire allowed by NEC. Wire types rated for 75°C
and 90°C are included.
Wire Type
75°C Wire
90°C Wire
Copper
6 AWG (16 mm2)
8 AWG (10 mm2)
Aluminum
4 AWG (25 mm2)
6 AWG (16 mm2)
1) Remove the Wiring End Cover from the Top Cover by removing the four securing screws as shown below.
2) Route the relevant cable/wire through the appropriate ¾ in opening as noted on the cover.
Note: If strain reliefs (i.e.: cable clamps, wire glands) are being used, they must be installed prior to routing
the wire, and the wire should route through the clamp.
3) Terminal connectors for DC wiring are located on the lower edge of the circuit board. Once the
wires have been installed, tighten the terminals with the screw located on the top of the terminals to 1.2Nm
(10.6lb-in). Be careful not to over tighten.
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a) Load: Maximum 10A DC Load
•Connect a cable from the TrakMax terminal marked load negative (–) to the negative terminal of your
DC load and tighten the screw.
•Connect a cable from the TrakMax terminal marked load positive (+) to the positive terminal of your DC
load and tighten the screw.
b) Battery: 30A Rated Charge Current
•Connect a cable from the TrakMax terminal marked battery negative (–) to the negative (–) battery
terminal and tighten the screw.
•Connect a cable from the TrakMax terminal marked battery positive (+) on the Solar charge controller to
the positive (+) battery terminal and tighten the screw.
IMPORTANT: A properly sized fuse must be placed in the positive wire connecting the charge controller to
the battery.
c) PV: Photovoltaic System
•Connect the PV array’s positive (+) output to the terminal marked PV positive (+) on the TrakMax and
tighten the screw.
•Connect the PV array’s negative (–) output to the terminal marked PV negative (–) on the TrakMax and
tighten the screw.
IMPORTANT: A properly sized fuse must be placed in the positive wire connecting the solar panels to the
charge controller.
4) Double Check All Connections to ensure they are secure.
5) Replace the Wiring Cover removed in step 1 and secure with the four screws.
6) Tighten the cable clamps (if applicable)
Insert Wire/Cable Here
Tighten Terminals Here
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