Smart choice for power

C35
C40
C60

Owner’s Manual

C-Series
Multifunction
DC Controller Manual Type

www.xantrex.com
C-Series Multifunction
DC Controller

Owner’s Guide
About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power
electronics and controls with products from 50 watt mobile units to one MW
utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and
backup power applications in both grid-connected and stand-alone systems.
Xantrex products include inverters, battery chargers, programmable power
supplies, and variable speed drives that convert, supply, control, clean, and
distribute electrical power.
Trademarks
C-Series Multifunction DC Controller is a trademark of Xantrex International.
Xantrex is a registered trademark of Xantrex International.
Other trademarks, registered trademarks, and product names are the property of
their respective owners and are used herein for identification purposes only.
Notice of Copyright
C-Series Multifunction DC Controller Owner’s Guide © November 2003 Xantrex
International. All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC.
(“XANTREX”)
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF
ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER
DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER
DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF
THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE
ENTIRELY AT THE USER’S RISK.
Date and Revision
November 2003 Revision D
Part Number
975-0004-01-02 Rev D
Contact Information
Telephone: 1 800 670 0707 (toll free North America)
1 360 925 5097 (direct)
Fax: 1 800 994 7828 (toll free North America)
1 360 925 5143 (direct)
Email: [email protected]
Web: www.xantrex.com
About This Guide

Purpose
The purpose of this Guide is to provide explanations and
procedures for installing, operating, maintaining, and
troubleshooting the C-Series Multifunction DC Controller.

Scope
This Guide provides safety guidelines, detailed planning and
setup information, procedures for installing the inverter, as
well as information about operating and troubleshooting the
unit. It does not provide details about particular brands of
batteries. You need to consult individual battery
manufacturers for this information.

Audience
This Guide is intended for anyone who needs to install and
operate the C-Series Multifunction DC Controller. Installers
should be certified technicians or electricians.

Organization
This Guide is organized into four chapters and three
appendices.
Chapter 1 describes features and functions of the C-Series
Multifunction DC Controller.

iii
About This Guide

Chapter 2 contains information and procedures to install

C-Series Multifunction DC Controller.
Chapter 3 contains information about the operation of a
C-Series Multifunction DC Controller.
Chapter 4, “Troubleshooting” contains information about
identifying and resolving possible problems with systems
using a C-Series Multifunction DC Controller.
Appendix A, “Specifications” provide the specifications for
the C-Series Multifunction DC Controller.
Appendix B, “Batteries” describes types of batteries.
Appendix C, “Diversion Loads” provides additional
information about Diversion Loads.

Conventions Used
The following conventions are used in this guide.

WARNING
Warnings identify conditions that could result in personal injury or
loss of life.

CAUTION
Cautions identify conditions or practices that could result in
damage to the unit or to other equipment.

Important: These notes describe an important action item or

an item that you must pay attention to.

iv 975-0004-01-02 Rev D
 About This Guide

Abbreviations and Acronyms

ASC Authorized Service Center
BTS Battery Temperature Sensor
CM C-Series Meter
CM/R C-Series Meter - Remote
DC Direct Current
LCD Liquid Crystal Display
LED Light Emitting Diode
LVD Low Voltage Disconnect
LVR Low Voltage Reconnect
RE Renewable Energy

Related Information
You can find more information about Xantrex Technology
Inc. as well as its products and services at
www.xantrex.com.

975-0004-01-02 Rev D v
vi
Important Safety Instructions

WARNING
This manual contains important safety instructions that should be
followed during the installation and maintenance of this product. Be
sure to read, understand, and save these safety instructions.

General Safety Instructions

• All electrical work must be done in accordance with
local, national, and/or international electrical codes.
• Before installing or using this device, read all instructions
and cautionary markings located in (or on) this guide, the
controller, the batteries, PV array, and any other
equipment used.
• This product is designed for indoor mounting only. Do
not expose this unit to rain, snow or liquids of any type.
In outdoor installations, the C-Series controller must be
installed in a rainproof enclosure to eliminate exposure to
rain or water-spray.
• To reduce the chance of short-circuits, use insulated tools
when installing or working with the inverter, the
controller, the batteries, or any DC source (e.g., PV,
hydro, or wind).
• Remove all jewelry. This will greatly reduce the chance
of accidental exposure to live circuits.
• The controller contains more than one live circuit
(batteries and PV array, wind, or hydro). Power may be
present at more than one source.
• This product contains no user serviceable parts. Do not
attempt to repair this unit unless fully qualified.

975-0004-01-02 Rev D vii

Safety

Battery Safety Information

• Always wear eye protection, such as safety glasses, when
working with batteries.
• Remove all jewelry before working with batteries.
• Never work alone. Have someone assist you with the
installation or be close enough to come to your aid when
working with batteries.
• Always use proper lifting techniques when handling
batteries.
• Always use identical types of batteries.
• Never install old or untested batteries. Check each
battery’s date code or label to ensure age and type.
• Batteries should be installed in a well-vented area to
prevent the possible buildup of explosive gasses. If the
batteries are installed inside an enclosure, vent its highest
point to the outdoors.
• When installing batteries, allow at least 1 inch of air
space between batteries to promote cooling and
ventilation.
• NEVER smoke in the vicinity of a battery or generator.
• Always connect the batteries first, then connect the
cables to the inverter or controller. This will greatly
reduce the chance of spark in the vicinity of the batteries.
• Use insulated tools when working with batteries.
• When connecting batteries, always verify proper voltage
and polarity.
• Do not short-circuit battery cables. Fire or explosion can
occur.
• In the event of exposure to battery electrolyte, wash the
area with soap and water. If acid enters the eyes, flood
them with running cold water for at least 15 minutes and
get immediate medical attention.
• Always recycle old batteries. Contact your local
recycling center for proper disposal information.

viii 975-0004-01-02 Rev D

 Battery Safety Information

CAUTION:
A battery can produce the following hazards to personal safety:
• electrical shock,
• burn from high-short-circuit current, and/or
• fire or explosion from vented gasses.
Observe proper precautions when working with or around batteries.

975-0004-01-02 Rev D ix
x
Contents

Important Safety Instructions - - - - - - - - - - - - - - - - - -vii

1 Introduction
Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Operating Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Charge Control Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
Three-Stage Battery Charging - - - - - - - - - - - - - - - - - - - 4
Battery Temperature Compensation - - - - - - - - - - - - - - - 6
Manual or Auto Equalization Charge - - - - - - - - - - - - - - 6
Load Control Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Controller Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
Photovoltaic Charge Controller - - - - - - - - - - - - - - - - - - - - - 7
Automatic PV Array Night Disconnect- - - - - - - - - - - - - 8
Diversion Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
Diversion Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
Load Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Low Voltage Disconnect - - - - - - - - - - - - - - - - - - - - - 11
Low Voltage Reconnect - - - - - - - - - - - - - - - - - - - - - - 11
Optional Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

2 Installation
Pre-Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
Removing the Top Cover - - - - - - - - - - - - - - - - - - - - - - - - 14
Removing Knockouts - - - - - - - - - - - - - - - - - - - - - - - - - - 14
Mounting the Controller - - - - - - - - - - - - - - - - - - - - - - - - 16
Configuring the C-Series Controller - - - - - - - - - - - - - - - - - - - 18
Jumper Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
Operating Mode Jumper- - - - - - - - - - - - - - - - - - - - - - 20
Voltage Jumper- - - - - - - - - - - - - - - - - - - - - - - - - - - - 20

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Contents
Automatic/Manual Battery Equalization (EQ) and Low
Voltage Reconnect (LVR) Jumper - - - - - - - - - - - - - - 21
Adjusting the C-Series Voltage Settings - - - - - - - - - - - - - - - - - 22
Setting Voltage Parameters for Charge Control Mode- - - - - 22
Setting Voltage Parameters for Load Control Mode - - - - - - 24
Setting Voltage Parameters Diversion Control Mode - - - - - 26
Setting Voltage Parameters for Alkaline Batteries - - - - - - - 26
Using a Digital Voltmeter to Adjust Voltage Settings - - - - - 28
Equalization Charging- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
Manual Equalization - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
Automatic Equalization - - - - - - - - - - - - - - - - - - - - - - - - - 32
Terminating the Equalization Process - - - - - - - - - - - - - - - 33
Temperature Compensation - - - - - - - - - - - - - - - - - - - - - - - - - 33
Temperature Compensation Based on Battery Type - - - - - - 34
Automatic Battery Temperature Compensation - - - - - - - - - 34
Manual Battery Temperature Compensation - - - - - - - - - - - 36
Grounding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38
DC Terminal Connector Locations - - - - - - - - - - - - - - - - - 38
Terminal Torque Requirements - - - - - - - - - - - - - - - - - 39
Wire Size and Over-current Protection Requirements - - - - - 39
Current Rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39
Minimum Recommended Wire Gauge - - - - - - - - - - - - 40
Surge Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
Over-current Protection - - - - - - - - - - - - - - - - - - - - - - 41
Long-distance wire runs - - - - - - - - - - - - - - - - - - - - - - 42
Maximum One-way Distance and Wire Size - - - - - - - - 42
PV Charge Control Mode Wiring - - - - - - - - - - - - - - - - - - 44
Diversion Control Mode Wiring - - - - - - - - - - - - - - - - - - - 46
DC Load Control Mode Wiring- - - - - - - - - - - - - - - - - - - - 48
Installing Optional Accessories- - - - - - - - - - - - - - - - - - - - - - - 50
Installing a Digital Display- - - - - - - - - - - - - - - - - - - - - - - 50
Installing the Battery Temperature Sensor - - - - - - - - - - - - 51
Reinstalling the Faceplate - - - - - - - - - - - - - - - - - - - - - - - - - - 52

xii 975-0004-01-02 Rev D

 Contents

3 Operation
Basic Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
LED Status Indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55
Charge Control or Diversion Control Indications (Green) - - 56
Blinking Green - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
Solid Green - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
Equalization Mode Indication (Red/green) - - - - - - - - - 58
Load Control Indications (Red) - - - - - - - - - - - - - - - - - - - - 58
Blinking Red - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
Solid Red- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
Error Mode Indication (Orange) - - - - - - - - - - - - - - - - - - - 59
Over-temperature Condition - - - - - - - - - - - - - - - - - - - 59
Over-Current Condition - - - - - - - - - - - - - - - - - - - - - - 59
Low-voltage Disconnect Condition - - - - - - - - - - - - - - 60
Reconnecting to Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
Reset Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

4 Troubleshooting
PV Charge Control Troubleshooting - - - - - - - - - - - - - - - - - - - 64
Diversion Control Troubleshooting - - - - - - - - - - - - - - - - - - - - 66
Load Control Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - 68

A Specifications
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - 70
Features and Options Specifications - - - - - - - - - - - - - - - - - - - 71
Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - 72

B Batteries
Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 74
Automotive Batteries- - - - - - - - - - - - - - - - - - - - - - - - - - - 74
Maintenance-Free Batteries - - - - - - - - - - - - - - - - - - - - - - 74
Deep-Cycle Batteries- - - - - - - - - - - - - - - - - - - - - - - - - - - 74
Sealed Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75
NiCad and NiFe Batteries - - - - - - - - - - - - - - - - - - - - - - - 76
975-0004-01-02 Rev D xiii
Contents
Battery Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76
Equalization Charging- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
Equalization Setpoints (Non-Sealed Batteries Only) - - - - - - 79

C Diversion Loads
Diversion Load Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82

Warranty and Product Information

Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
Disclaimer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86
Return Material Authorization Policy - - - - - - - - - - - - - - - - - - 87
Return Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88
Out of Warranty Service - - - - - - - - - - - - - - - - - - - - - - - - - - - 88
Information About Your System - - - - - - - - - - - - - - - - - - - - - 89

Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91

xiv 975-0004-01-02 Rev D

Figures

Figure 1-1 C-Series Multifunction DC Charge Controllers - - - - - - 2

Figure 1-2 3-stage Battery Charging Process - - - - - - - - - - - - - - - 5
Figure 1-3 PV Charge Controller - - - - - - - - - - - - - - - - - - - - - - - 7
Figure 1-4 Diversion Controller - - - - - - - - - - - - - - - - - - - - - - - - 9
Figure 1-5 Load Controller - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Figure 1-6 Decal Displaying Load Control Voltage Settings - - - - 12
Figure 1-7 Optional Accessories - CM/R, CM, and BTS- - - - - - - 12
Figure 2-1 Removing the Front Cover - - - - - - - - - - - - - - - - - - - 14
Figure 2-2 C-Series Dimensions and Knockout Locations
(Not to Scale) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
Figure 2-3 Mounting the C-Series Multifunction DC Controller - 17
Figure 2-4 Jumper Positions- - - - - - - - - - - - - - - - - - - - - - - - - - 18
Figure 2-5 Circuit Board Components - - - - - - - - - - - - - - - - - - - 19
Figure 2-6 Mode of Operation Jumper - - - - - - - - - - - - - - - - - - - 20
Figure 2-7 Voltage Selection Jumper- - - - - - - - - - - - - - - - - - - - 20
Figure 2-8 EQ/LVR Jumper and Reset Switch - - - - - - - - - - - - - 21
Figure 2-9 Bulk and Float Charge Potentiometers (pots)- - - - - - - 22
Figure 2-10 Bulk and Float Charge Settings for Charge/Diversion
Control Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
Figure 2-11 Potentiometers with Decal for LVR and LVD Settings 24
Figure 2-12 LVR and LVD Settings for Load Control Mode- - - - - 25
Figure 2-13 R46 Resistor Location - - - - - - - - - - - - - - - - - - - - - - 26
Figure 2-14 Voltage Settings with R46 Resistor Clipped - - - - - - - 27
Figure 2-15 Test Points for Adjusting Voltage Using a DVM - - - - 29
Figure 2-16 Manual Equalization Settings - - - - - - - - - - - - - - - - - 30
Figure 2-17 Front Panel LED and Reset Switch Location - - - - - - - 31
Figure 2-18 Auto Equalization Settings - - - - - - - - - - - - - - - - - - - 32
Figure 2-19 Terminating the Equalization Charge - - - - - - - - - - - - 33
Figure 2-20 Grounding the C-Series Chassis - - - - - - - - - - - - - - - 37
Figure 2-21 DC Connection Terminals - - - - - - - - - - - - - - - - - - - 39

xv
Figures
Figure 2-22 AWG Wire Gauge Reference Chart - - - - - - - - - - - - - 40
Figure 2-23 PV Charge Control Mode Wiring - - - - - - - - - - - - - - 45
Figure 2-24 Diversion Control Mode Wiring - - - - - - - - - - - - - - - 47
Figure 2-25 Load Control Mode Wiring - - - - - - - - - - - - - - - - - - 49
Figure 2-26 Installing a Digital Display - - - - - - - - - - - - - - - - - - - 50
Figure 2-27 Installing the BTS - - - - - - - - - - - - - - - - - - - - - - - - - 51
Figure 2-28 Re-installing the CM Faceplate - - - - - - - - - - - - - - - - 52
Figure 3-1 C-Series Status LED and Reset Button Location - - - - 54
Figure 3-2 C-Series Front Panel Label - - - - - - - - - - - - - - - - - - - 55
Figure 3-3 Reset Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

xvi 975-0004-01-02 Rev D

Tables

Table 2-1 Factory Default Settings for C-Series Controllers- - - - 19

Table 2-2 Variances in Charging Voltage based on
Battery Temperature - - - - - - - - - - - - - - - - - - - - - - - 35
Table 2-3 Minimum Wire Size - - - - - - - - - - - - - - - - - - - - - - - 41
Table 2-4 One-Way Wire Distance and Wire Size - - - - - - - - - - 43
Table 3-1 Battery Voltage LED Indicators - - - - - - - - - - - - - - - 56
Table 4-1 PV Charge Control Problems - - - - - - - - - - - - - - - - - 64
Table 4-2 Diversion Control Problems - - - - - - - - - - - - - - - - - - 66
Table 4-3 Load Control Problems - - - - - - - - - - - - - - - - - - - - - 68
Table A-1 Electrical Specifications- - - - - - - - - - - - - - - - - - - - - 70
Table A-2 Features and Options Specifications- - - - - - - - - - - - - 71
Table A-3 Environmental Specifications - - - - - - - - - - - - - - - - - 72
Table B-1 Typical Bulk and Float Setpoints for Batteries - - - - - - 79
Table C-1 Power Dissipation - - - - - - - - - - - - - - - - - - - - - - - - - 82

xvii
xviii
1 Introduction

Chapter 1 describes features and functions of the

C-Series Multifunction DC Controller.

For information on: See:

“Features” page 2
“Operating Modes” page 3
“Controller Functions” page 7
“Optional Accessories” page 12
Introduction

Features
The C35/C40/C60 (C-Series) controllers can be used with
12-volt, 24-volt, or 48-volt DC systems (depending upon
model) as Charge Controller or a Load Controller.

C35 C40 C60

Figure 1-1 C-Series Multifunction DC Charge Controllers

Numerous features are provided standard to maximize the
performance of the system:
• Solid-state Pulse Width Modulated (PWM) charging
process with three-stage control, temperature
compensation, and manual or automatic equalization to
maximize system performance and increase battery life.
• Multi color LED with easy to read mode/status label.
• 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.
• Adjustment of charge setpoints is provided by rotary
controls (potentiometers) with removable knobs.
Calibrated scales and test points allow precise
adjustments of settings.
• Over-temperature protection for the electronic circuitry
when used in hot environments (over 113 °F/45 °C).

2 975-0004-01-02 Rev D
 Operating Modes

• Indoor-type, powder-coated enclosure, for wall

mounting.
• Conformal-coated circuit boards, plated terminals,
powder-coated metal components, and stainless steel
fasteners improves tolerance to hostile environments.
• Meets National Electrical Code (NEC) and other
international controller specifications.
• The C35, C40 and C60 models are UL listed to the
U.S. UL Standard 1741 (1st edition), and Canada
(CSA-C22.2 No. 107.1-95).
• 2-year limited warranty.

Operating Modes
The DC controller is a critical component in any solar, wind
or hydro power generation system and protects the batteries
from over-discharge and over-charge conditions. The
C-Series has two operating modes (Charge Control mode and
Load Control mode determined by the Operating mode
jumper (See Figure 2-5). These two different operating
modes allow the C-Series to be installed and function as three
different DC controllers.
• Charge Control Mode
• PV Charge Controller - controls charging in PV
installations.
• Diversion Controller – used in PV, wind, or hydro
installations to divert any excess energy to a diversion
load and in the case of a wind or hydro generator, helps
to prevent over-spin damage.
• Load Control Mode
• Load Controller - prevents damage to the battery from
over-discharge during periods of poor charging or
excessive loads.

975-0004-01-02 Rev D 3
Introduction

Important: The C-Series controller cannot operate in more

than one function at the same time. If several functions are
required in a system, a dedicated controller must be used for each
function.

Charge Control Mode

In the Charge Control mode, the C-Series controls how the
batteries are charged by the DC source (solar, wind, or
hydro). It uses a 3-stage charging protocol to maintain battery
voltage at bulk and/or float levels.
When charging, the C-Series controller monitors the batteries
and depending on how it is wired will regulate the PV current
(as a PV Charge Controller) or divert excess energy from PV,
hydro, or wind to a DC load (as a Diversion Controller) and
allows the battery to charge according to user-defined
settings based on the amount of DC power available.
When the C-Series operates in the Charge Control mode, it
provides:
• three-stage charging of battery voltage,
• automatic temperature compensation (if the BTS is used),
and
• automatic or manual equalization charging.

Three-Stage Battery Charging

The three-stage charging process results in faster charging
compared to on-off relay type or constant voltage solid-state
regulators. Faster recharging increases the performance of the
system by storing more of the PV array’s limited output. The
final float voltage setting reduces battery gassing, minimizes
watering requirements and ensures complete battery
recharging. The C-Series will use this protocol in either PV
Charge Control mode or in Diversion Control mode. It does
not charge the batteries when in Load Control mode. Battery
voltage and current vary during the three-stage charging
process as follows.

4 975-0004-01-02 Rev D
 Operating Modes

Bulk Stage
During this stage, the batteries are charged at the bulk voltage
setting and maximum current output of the DC source. When
the battery voltage reaches the bulk voltage setting, the
controller activates the next stage (absorption).

Absorption Stage
During this stage, the voltage of the battery is held at the bulk
voltage setting until an internal timer has accumulated one
hour. Current gradually declines as the battery capacity is
reached.

Float Stage
During this stage, the voltage of the battery is held at the float
voltage setting. Full current can be provided to the loads
connected to the battery during the float stage from the PV
array. When battery voltage drops below the float setting for
a cumulative period of one hour, a new bulk cycle will be
triggered.

Bulk Stage Absorption Stage Floa t Stage

Charging Bulk Vol ts Setti ng

Started
Absorpti on Time Float Volts Setti ng

DC Voltage Increasing Vol tage Constant Vol tage Reduced Vol tage
0 vol ts

Max Amps

DC Current Constant Current Reducing Current Reduced Current

0 amps

Time

Figure 1-2 3-stage Battery Charging Process

975-0004-01-02 Rev D 5
Introduction

Battery Temperature Compensation

The optional Battery Temperature Sensor (BTS)
automatically adjusts the charging process of the C-Series
controller. With the BTS installed, the C-Series will increase
or decrease the battery charging voltage depending on the
temperature of the battery to optimize the charge to the
battery and maintain optimal performance of the battery.
If not using the BTS, the voltage settings for charging will
need to be adjusted based on the temperature of the
environment around the batteries and on the type of batteries
being used.
See “Temperature Compensation” on page 33 for information
on how to set the voltage.

Manual or Auto Equalization Charge

The C-Series controller can be used to manually or
automatically provide the battery bank with an equalize
charge. Factory default setting is for MANUAL Equalization
charging. Be sure to be familiar with all the cautions and
warnings concerning equalization charging batteries or
damage to batteries can occur.

Load Control Mode

In the Load Control mode, the C-Series controls when to
remove a load or loads from the system when an
over-discharge or over-load situation occurs. The C-Series
controller uses the user-adjustable setpoints to determine
when to connect or reconnect loads depending on battery
voltage. A load controller prevents damage to the battery
from over-discharge during periods of poor weather or
excessive loads. The unit does not charge the batteries when
in this function.

6 975-0004-01-02 Rev D
 Controller Functions

Controller Functions
The C-Series can be configured to function as three different
controllers:
• PV Charge Controller (Charge Control mode)
• Diversion Controller (Charge Control mode)
• Load Controller (Load Control mode)

Photovoltaic Charge Controller

The C-Series controller can operate as a Photovoltaic Charge
Controller, also called a “series regulator”. Depending on the
model, the controller can regulate up to 60 amps of
continuous photovoltaic (PV) array current at 12 or 24 volts
(C60 or C35 models), or 12-, 24- or 48-volts DC (C40 model)
for charging batteries. This rating includes the NEC required
derating.

Figure 1-3 PV Charge Controller

If the PV array’s output increases above the rated amp level

due to reflection or “edge of cloud effect,” the controller will
continue to operate until the heatsink reaches a maximum
safe operating temperature. This will take several minutes to
occur, depending upon the ambient temperature involved.
When the heatsink reaches the maximum safe temperature,
the controller will reduce the current, cooling the transistors
and the heatsink.

975-0004-01-02 Rev D 7
Introduction

If the current from the PV array reaches 85 amps, the

controller will turn off to protect the circuitry. In the event of
a shutdown, the controller automatically resets itself after
10 minutes (if overcurrent condition is no longer present).
See “Operating Mode Jumper” on page 20 for information on
configuring this function.

Automatic PV Array Night Disconnect

When using PV Charge Control mode, the PV array is
automatically disconnected from the battery at night to
prevent reverse leakage of power. This eliminates the need
for a blocking diode between the battery and the PV array. If
thin-film or amorphous solar modules are being used, diodes
may still be required to prevent damage from partial shading
conditions.
Check the documentation provided with the PV modules.

Diversion Controller
The C-Series controller can operate as a Diversion Controller,
also called a shunt regulator, to manage battery charging from
alternative energy sources such as PV, wind or hydroelectric
generators. A diversion controller monitors battery voltage
and, when the voltage exceeds the settings for your charge
stage (whether bulk or float), the power is diverted from the
source (solar, wind, or hydro generator) to a “dump” load
which will dissipate the excess power into heat.
When used for this purpose, the C-Series controller varies an
amount of battery voltage to a “dump load” in order to
redirect the excess power generated from over-charging the
batteries. This allows the charging source to remain under
constant load to prevent an over-speed condition which could
occur if the charging source is suddenly disconnected from
the battery–as series regulators do.
Consult your dealer for recommendations on diversion load
type and regulator size.

8 975-0004-01-02 Rev D
 Controller Functions

Figure 1-4 Diversion Controller

Diversion Loads
Diversion control requires a separate “dump” load 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. A diversion load that draws
about 25% more current than the charging source’s maximum
output capability is usually suitable for use with the C-Series
controller.
See Appendix C, “Diversion Loads” for additional
information on types of diversion loads.
See “Operating Mode Jumper” on page 20 for instructions on
enabling this mode.

975-0004-01-02 Rev D 9
Introduction

Important: If PV arrays are used with diversion control, it

may be necessary to install diodes to prevent night-time
back-feed. If in doubt, contact or consult with your local
renewable energy expert.

Important: If using multiple RE sources, use diodes/isolation

to prevent backfeed.

CAUTION: Damage to Batteries

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
allowing batteries to overcharge.
Diversion loads in excess of the controller’s rating are capable of
absorbing more power than the C-Series controller 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.

Load Controller
The C-Series controller can operate as a Low Voltage
Disconnect (LVD) for DC loads to prevent over-discharge to
batteries during periods of poor charging or excessive loads.
The C-Series controller uses the user-adjustable setpoints to
determine when to disconnect or reconnect loads depending
on battery voltage.
When used as a DC load controller, the settings of the LVR
and LVD are controlled by two rotary potentiometers (also
called pots) on the circuit board.
The scale on the adjustment potentiometers differ from the
scale used for other functions. A decal with the appropriate
adjustment scale is included with the C-Series. To apply the
decal, gently pull off the knobs of the potentiometers and
place this decal on the circuit board. After the decal is in
place, replace the knobs. The EQ jumper determines manual

10 975-0004-01-02 Rev D
 Controller Functions

or automatic reconnect when the C-Series is used as a load

controller. Do not use this decal if using the C-Series
controller as a PV Charge Controller or Diversion Controller.

Low Voltage Disconnect

When configured as a load controller, the C-Series controller
will disconnect the load from the batteries when it reaches the
LVD setting. There will be a 6-minute delay after the voltage
drops below the Low Voltage Disconnect (LVD) setting
before the controller actually disconnects the load.

Low Voltage Reconnect

It can also provide automatic reconnection of the loads at the
LVR (Low Voltage Reconnect) setting. Reconnection of the
load is allowed once the battery voltage has exceeded the
Low Voltage Reconnect (LVR) setting.
Loads are either automatically or manually reconnected when
battery voltage exceeds the Low Voltage Reconnect (LVR)
setting for 6 minutes.
See “Operating Mode Jumper” on page 20 for instructions on
enabling this mode.

Figure 1-5 Load Controller

Important: When using the DC Load Control mode:

• Do not temperature-compensate these settings.
• Do not install the optional battery temperature
compensation sensor.

975-0004-01-02 Rev D 11
Introduction

Potentiometer knobs

Attach decal over

potentiometers for
Load Control
Settings

Figure 1-6 Decal Displaying Load Control Voltage Settings

Optional Accessories
The follow accessories can be purchased for use with the
C-Series Multifunction DC Controller:
• Display Meters: The CM faceplate or CM/R remote
display provide a digital display for monitoring the
C-Series controller’s operation. The CM faceplate
attaches directly to the front of the C-Series controller.
The CM/R is intended for remote applications. These
meters provide a digital display of current, voltage,
amperage, and amp hours.
• Battery Temperature Sensor (BTS): The BTS is
installed on the side of the battery and attaches to the
circuit board inside the C-Series controller. It provides
accurate sensing of the battery temperature and uses this
reading to control charging. Using this accessory can
extend battery life and improve overall charging.

BTS

CM/R CM

Figure 1-7 Optional Accessories - CM/R, CM, and BTS

12 975-0004-01-02 Rev D
2 Installation

Chapter 2 contains information and procedures to install

C-Series Multifunction DC Controller.

For information on: See:

“Pre-Installation” page 14
“Mounting the Controller” page 16
“Configuring the C-Series Controller” page 18
“Adjusting the C-Series Voltage Settings” page 22
“Grounding” page 37
“Wiring” page 38
“Installing Optional Accessories” page 50
“Installing the Battery Temperature Sensor” page 51
Installation

Pre-Installation
The instructions that follow are applicable to the typical
installation. For special applications, consult a qualified
electrician or your Xantrex Certified Dealer. Installation
procedures will vary according to your specific application.

Important: Installations should meet all local codes and

standards. Installations of this equipment should only be
performed by skilled personnel such as qualified electricians and
Certified Renewable Energy (RE) System Installers. For a list of
Xantrex Certified RE dealers, please visit our website at
www.XantrexREdealers.com.

Removing the Top Cover

Access the inside of the controller by removing the four
phillips screws (#10-32 x 3/8" SMS screws) on the front
cover of the unit.

Remove these
phillips screws (x4)
from the front cover
to access the inside
of the controller.

Figure 2-1 Removing the Front Cover

Removing Knockouts
Six dual-knockouts are provided to accommodate the
necessary wiring of the C-Series controller. Be sure to
remove any metal shavings created by removing the

14 975-0004-01-02 Rev D
 Pre-Installation

knockouts before making any wiring connections. It is also

recommended to use bushings or conduits to protect the
wiring from damage from rough edges in the knockout holes.

Heatsink not Keyhole Slots for

included on C35 mounting

2"
(51 mm)

8"
(203 mm)

Additional Mounting
Holes (x4)
6 7/8"
8" (174 mm)
(203 mm)

½ and ¾"
2 Dual-Knockouts

2 ¼” Side View 3 5/8” Rear View

(64 mm) (93 mm)

5”
(127 mm)

1 This distance varies per model:

C35 = 3/8"
C40, C60 = 5/8"

2 ¾ and 1"
Dual-Knockouts (x4)
(1 on each side and 2 on the bottom of chassis)

Figure 2-2 C-Series Dimensions and Knockout Locations (Not to Scale)

975-0004-01-02 Rev D 15
Installation

Mounting the Controller

The C-Series controller is designed for indoor mounting.
Care should be taken in selecting a location and when
mounting the enclosure. Avoid mounting it in direct sunlight
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.

CAUTION: Damage to C-Series Controller

Install the C-Series controller in a dry, protected location away
from sources of high temperature, moisture, and vibration.
Exposure to saltwater is particularly destructive. Corrosion is not
covered by the warranty.

To mount the C-Series controller:

1. Remove the faceplate on the controller.
2. Place the controller on the desired mounting surface and
mark the location of the keyhole slots on the wall.
3. Move the controller out of the way, and secure two
mounting screws in the locations marked. Leave the
screw heads backed out approximately ¼ inch (6 mm)
or less.
4. Place the controller onto the screws and pull it down into
the keyhole slots.
5. Then insert the two more screws in two of the four
additional mounting holes provided to secure the
enclosure onto the wall.
6. Provide either strain-relief clamps or conduit to prevent
damage to the circuit board and terminal block from
pulling on the wires.

16 975-0004-01-02 Rev D
 Pre-Installation

WARNING: Explosion/Corrosion Hazard

Do not locate the C-Series controller in a sealed compartment with
the batteries. Batteries can vent hydrogen-sulfide gas, which is
corrosive to electronic equipment. Batteries also generate hydrogen
and oxygen gas that can explode when exposed to a spark.

If using “sealed” batteries, the controller can be mounted in

the same enclosure as long as it is adequately ventilated.

Place keyhole slots on the back of the

controller over the mounting screws.

Approximately
¼ inch

Mounting
Screws

Mounting Surface

Secure in place with

2 more screws.

Figure 2-3 Mounting the C-Series Multifunction DC Controller

975-0004-01-02 Rev D 17
Installation

Configuring the C-Series Controller

Before making any wiring connections to the C-Series
controller, it must be configured for the desired mode of
operation. The following sections describe the how to
configure the unit for the desired application and function.

Jumper Settings
Three sets of jumpers are located on the right side of the
controller’s circuit board. These jumpers control
equalization, low voltage reconnect, battery voltage, and
operating modes. They must be installed correctly for the unit
to operate to its maximum potential.
To enable a selection, carefully slide the jumper over the top
of both pins. This is called installing the jumper.
To disable a selection, carefully slide the jumper over only
one of the pins. This is called removing the jumper.

Jumper Removed
(Jumper is only on one pin)

Jumper
Jumper Installed
(Jumper is on both pins)

Figure 2-4 Jumper Positions

The factory default settings are shown in Table 2-1, “Factory
Default Settings for C-Series Controllers” on page 19.

Important: Use extreme caution when installing and removing

jumpers so as not to bend the pins.

18 975-0004-01-02 Rev D
 Configuring the C-Series Controller

Table 2-1 Factory Default Settings for C-Series Controllers

Setting C35, C40 and C60
Battery Voltage 12 volts DC
Equalize/LVR Manual Equalization
Operating Mode Charge Control

NiCad Setting
Selection R46
Resistor

Load Control
Decal

EQ/LVR
Jumper

Operating
Mode Jumper

Reset Switch

Potentiometers

Voltage Jumper

Battery
Temperature
Sensor Port

DC Terminal Connectors
CM or CM/R Port

Note: This photograph shows the Load Control Voltage decal installed on the
circuit board over the potentiometers.

Figure 2-5 Circuit Board Components

975-0004-01-02 Rev D 19
Installation

Operating Mode Jumper

This jumper determines the operating mode. Place the jumper
over the pins that correspond to the desired mode.
• Charge Control (PV Charge Controller or Diversion
Controller)
• Load Control (Load Controller)
Factory default setting is Charge Control mode.

Charge/Load
Control
Jumper Charge Control Mode

Load Control Mode

Figure 2-6 Mode of Operation Jumper

Voltage Jumper
The voltage jumper determines the voltage of the system that
the controller will be used with. To set the voltage, place the
jumper over the two pins adjacent to the legend for the
voltage of your system: 12, 24, 48. Factory setting is 12 volts
for the C35, C40, and C60.

C40 Models
12 Volt Position
24 Volt Position
48 Volt Position

C35 and C60

Models
12 Volt Position
24 Volt Position

Figure 2-7 Voltage Selection Jumper

20 975-0004-01-02 Rev D
 Configuring the C-Series Controller

Automatic/Manual Battery Equalization (EQ) and Low Voltage

Reconnect (LVR) Jumper
Depending on the mode of operation chosen, this jumper
enables:
• automatic or manual battery equalization
(Charge Control mode), or
• automatic or manual reconnect in the event of low
voltage event (Load Control mode).
When AUTO is enabled in the Charge Control mode, the unit
will perform an equalization charge every 30 days. This can
be done manually by using Reset Switch on the side of the
controller chassis.
When AUTO is enabled in Load Control mode, the unit will
reconnect automatically when voltage at the BATTERY
POSITIVE terminal exceeds the LVR setting. This can also be
done manually by using Reset Switch on the side of the
controller chassis.
The factory default setting is MANUAL EQUALIZATION
(Charge Control mode).
Place the jumper over the pins for the desired selection.

EQ/LVR Jumper

MANUAL
AUTO

Figure 2-8 EQ/LVR Jumper and Reset Switch

See “Error Mode Indication (Orange)” on page 59 for
instructions on how to use the Reset Switch in relation to this
function.

975-0004-01-02 Rev D 21
Installation

Adjusting the C-Series Voltage Settings

The charging voltage setpoints and voltage reconnect/
disconnect setting of the controller are adjustable using two
rotary potentiometer controls. The knobs are removable to
reduce the likelihood of accidental mis-adjustment if
bumped.
Calibrated scales, shown as scale marks, are provided to
allow setting of the control without requiring the use of a
digital voltmeter.
For more information regarding bulk and float charging
voltages, see “Three-Stage Battery Charging” on page 4.

Setting indicator

Scale Marks Potentiometers

Figure 2-9 Bulk and Float Charge Potentiometers (pots)

Setting Voltage Parameters for Charge Control Mode

To set the controller to a specific voltage, point the setting
indicator at the scale mark representing the desired voltage.
The potentiometer scale for BULK charge voltage is
calibrated as follows:
• 12-volt system: 13.0 to 15.0 volts
in increments of 0.2 volts,
• 24-volt system: 26.0 to 30.0 volts
in increments of 0.4 volts,
• 48-volt system: 52.0 to 60.0 volts
in increments of 0.8 volts.

22 975-0004-01-02 Rev D
 Adjusting the C-Series Voltage Settings

For FLOAT charge voltage, the potentiometer scale is

calibrated follows:
• 12-volt system: 12.5 to 14.5 volts
in increments of 0.2 volts,
• 24-volt system: 25.0 to 29.0 volts
in increments of 0.4 volts, and
• 48-volt system: 50.0 to 58.0 volts
in increments of 0.8 volts.

14.6 14.8 15.0 29.2 29.6 30.0

14.4 28.8
14.2 28.4

14.0 BULK (CHG) 28.0 BULK (CHG)

13.8 27.6
13.6 27.2
13.4 13.2 13.0 26.8 26.4 26.0
14.1 14.3 14.5 28.2 28.6 29.0
13.9 27.8
13.7 27.4

13.5 FLOAT (CHG) 27.0 FLOAT (CHG)

13.3 26.6
13.1 26.2
12.5
12.9 12.7 25.8 25.4 25.0

12-Volt System Settings 24-Volt System Settings

58.4 59.2 60.0

57.6
56.8

56.0 BULK (CHG)

55.2
54.4
53.6 52.8 52.0
56.4 57.2 58.0
55.6
54.8

54.0 FLOAT (CHG)

53.2
52.4
51.6 50.8 50.0
48-Volt System Settings (C40 only)

Figure 2-10 Bulk and Float Charge Settings for Charge/Diversion

Control Mode

975-0004-01-02 Rev D 23
Installation

Setting Voltage Parameters for Load Control Mode

To change the Low Voltage Disconnect (LVD) and Low
Voltage Reconnect (LVR) settings, use the same BULK and
FLOAT potentiometers. However, when the C-Series
controller is used for DC Load Control, the potentiometer’s
scale calibration is altered from what is printed on the circuit
board.

BULK Setting LVR Setting

Potentiometer

FLOAT Setting LVD Setting

Potentiometer

Figure 2-11 Potentiometers with Decal for LVR and LVD Settings

A decal is provided with the C-Series with the proper scale

calibrations for the Load Control mode. The BULK
potentiometer becomes the Low Voltage Reconnect (LVR),
and the FLOAT potentiometer becomes the Low Voltage
Disconnect (LVD).
Place the sticker provided over the potentiometers. The knobs
may have to be removed for sticker placement, then
reinstalled. The sticker is packed inside the C-Series
controller (bottom of unit). If the decal is lost or unavailable,
you can recalculate the appropriate voltage settings as
follows:

The scale for the Low Voltage Reconnect setting is calibrated

as follows:
• 12-volt system: 12.0 to 14.0 volts
in increments of 0.2 volts,
• 24-volt system: 24.0 to 28.0 volts
in increments of 0.4 volts,
• 48-volt system: 48.0 to 56.0 volts
in increments of 0.8 volts.

24 975-0004-01-02 Rev D
 Adjusting the C-Series Voltage Settings

The scale for the Low Voltage Disconnect setting is

calibrated as follows:
• 12-volt system: 10.5 to 12.5 volts
in increments of 0.2 volts,
• 24-volt system: 21.0 to 25.0 volts
in increments of 0.4 volts, and
• 48-volt system: 42.0 to 50.0 volts
in increments of 0.8 volts.

13.6 13.8 14.0 27.2 27.6 28.0

13.4 26.8
13.2 L.V.R (LOAD) 26.4 L.V.R (LOAD)
LOW VOLTAGE 26.0 LOW VOLTAGE
13.0
RECONNECT 25.6
RECONNECT
12.8
12.6 25.2
12.4 12.2 12.0 24.8 24.4 24.0
12.1 12.3 24.2 24.6 25.0
12.5 23.8
11.9
11.7
L.V.D (LOAD)
23.4 L.V.D (LOAD)
11.5 LOW VOLTAGE 23.0 LOW VOLTAGE
11.3 DISCONNECT 22.6 DISCONNECT
11.1 22.2
10.5
10.9 10.7 21.8 21.4 21.0
12-Volt System Settings 24-Volt System Settings

54.4 55.2 56.0

53.6
52.8 L.V.R (LOAD)
52.0 LOW VOLTAGE
51.2
RECONNECT
50.4
49.6 48.8 48.0
48.4 49.2 50.0
47.6
46.8 L.V.D (LOAD)
46.0 LOW VOLTAGE
45.2 DISCONNECT
44.4
43.6 42.8 42.0
48-Volt System Settings (C40 only)

Figure 2-12 LVR and LVD Settings for Load Control Mode

975-0004-01-02 Rev D 25
Installation

Setting Voltage Parameters Diversion Control Mode

When the C-Series controller is configured for Diversion
Control mode, you can set the voltage at which the unit
begins diverting current to a diversion load (high voltage
diversion). Use the Charge Control scale for setting this
value.
See Figure 2-10 on page 23 for Charge Control scale settings.
The unit will continue diverting excess current to the
diversion load until the source voltage falls to or below the
BULK setting. After one hour at the BULK setting, the unit
will reduce the battery charging voltage to the FLOAT
voltage setting. This will usually result in more current being
diverted to the diversion load.

Setting Voltage Parameters for Alkaline Batteries

If using NiCad or NiFe batteries, the required charging
voltages may be higher than the designed settings of the
C-Series controller. Charging voltages can be augmented a
little, if required. This can be accomplished by clipping the
wire connecting the R46 Resistor to the circuit board. This
augmentation will raise the designed charge parameters by
2 volts for 12-volt systems, 4 volts for 24-volt systems and
8 volts for 48-volt systems.
See Figure 2-14 for the augmented voltage settings.

If using NiCad batteries,

clip this wire here. Do NOT
remove the R46 Resistor.

R46 Resistor
Circuit Board

Figure 2-13 R46 Resistor Location

26 975-0004-01-02 Rev D
 Adjusting the C-Series Voltage Settings

16.6 16.8 17.0 33.2 33.6 34.0

16.4 32.8
32.4
16.2

BULK (CHG) 32.0 BULK (CHG)

16.0
31.6
15.8
31.2
15.6
30.8 30.4 30.0
15.4 15.2 15.0
32.2 32.6 33.0
16.1 16.3 16.5 31.8
15.9
31.4
15.7
31.0 FLOAT (CHG)
15.5 FLOAT (CHG)
30.6
15.3 30.2
15.1 29.8 29.4 29.0
14.9 14.7 14.5
12-Volt System Settings 24-Volt System Settings

66.4 67.2 68.0

65.6
64.8

64.0 BULK (CHG)

63.2
62.4
61.6 60.8 60.0
64.4 65.2 66.0
63.6
62.8

62.0 FLOAT (CHG)

61.2
60.4
59.6 58.8 58.0

48-Volt System Settings (C40 only)

Figure 2-14 Voltage Settings with R46 Resistor Clipped

CAUTION: Damage to Batteries

It is not recommended to allow an equalize charge to occur if the
R46 Resistor is clipped. Higher charging voltages may damage the
batteries. Make sure the EQ/LVR jumper is on the MANUAL
Setting.

975-0004-01-02 Rev D 27
Installation

Using a Digital Voltmeter to Adjust Voltage Settings

A digital DC voltmeter (DVM) can be used to provide a more
accurate setting of voltage parameters. Test points are
provided at the mid-range on the scales for this purpose.
The potentiometers are equipped with removable knobs to
prevent accidental mis-adjustments. If the knobs are missing,
a 5/64" hex-head driver can be used to adjust the settings.
To test and adjust the voltage setting using a DVM:
1. Point the potentiometers to the mid-range position.
2. Connect a digital voltmeter from one of the common
negative terminals on the circuit board and the small test
point located to the left of each potentiometer at the
nine o’clock position. See Figure 2-15.
The test point provides a reading from 0 to 2 volts.
(Multiply this value by “2” for 24-volt system and by
“4” for 48-volt system.)
3. Add the value obtained in step 2 above to the lower value
of the adjustment range/voltage scale being used.

For example for a 12-volt system:

To set the BULK voltage to 14.4 volts:
1. Point the BULK potentiometer to the mid-range position.
2. Adjust the potentiometer until the DVM displays
1.4 volts (13.0 V + 1.4 V = 14.4 V).
For example for a 24-volt system:
To set BULK voltage to 28.2 volts:
1. Point the BULK potentiometer to the mid-range position.
2. Adjust the potentiometer until the DVM displays
1.1 volts (1.1 x 2 [24 volt] = 2.2 + 26.0 = 28.2).

28 975-0004-01-02 Rev D
 Adjusting the C-Series Voltage Settings

For example for a 48-volt system:

To set BULK voltage to 56.4 volts:
1. Point the BULK potentiometer to the mid-range position.
2. Adjust the potentiometer until the DVM displays
1.1 volts (1.1 x 4 [48 volt] = 4.4 + 52.0 = 56.4).

TEST POINTS for DVM

(center legs of
potentiometer)

Battery Common Negative

Terminals

Figure 2-15 Test Points for Adjusting Voltage Using a DVM

975-0004-01-02 Rev D 29
Installation

Equalization Charging

CAUTION: Damage to Batteries

Equalization should be done for standard electrolyte, vented
:

batteries only. Sealed, GEL cell, or NiCad batteries should not be

equalize-charged. Consult your battery supplier for details on
equalize-charging for the battery type in your system.

The C-Series offers either manual or automatic triggering of

the equalization charging process. Equalization charging is
the deliberate process of charging a battery (or battery bank)
at a high voltage for a set period of time to remix the
electrolyte and destratify the internal plates. Equalize
charging helps to remove sulfate buildup on the battery plates
and balances the charge of individual cells.
Equalization charging holds the voltage above the BULK
setting for 2 hours by 1 volt for 12-volt systems, 2 volts for
24-volt systems, and 4 volts for 48-volt systems.
The default setting for this feature is MANUAL. Automatic
equalization is enabled by moving the jumper located on the
right side of the circuit board above the reset switch to the
appropriate AUTO pin set. See Figure 2-18

Manual Equalize
(Default Setting)
Auto Equalize

Figure 2-16 Manual Equalization Settings

When automatic has been selected, an equalization charge
will occur every 30 days.
During the equalization process, the status LED indicates
equalization by alternately blinking green and red.

Important: The auto equalization period is reset when DC

power is removed from the controller.

30 975-0004-01-02 Rev D
 Equalization Charging

Manual Equalization
Manual equalization of the battery can be enabled by pressing
the Reset Switch on the right side of the C-Series until the
status LED indicator begins to alternate between red and
green. This could take about 10 seconds.

Front Panel LED

(flashes red/green
during equalization)
Reset
Switch
Access

Figure 2-17 Front Panel LED and Reset Switch Location

The equalization process will continue until the batteries have
been held at or above the bulk setting for two hours of
accumulated time. Once the battery voltage has been at or
above the bulk setting for a cumulative period of two hours,
the C-Series will return to the float stage of the charging
process.
During the equalization process, the status LED will alternate
between red and green and will not provide any other
mode/status indication. Large battery banks may need several
equalization cycles to fully stir the electrolyte and charge the
cells. These cycles should follow one another until the battery
voltage reaches the upper limit for the full two hours.

975-0004-01-02 Rev D 31
Installation

Automatic Equalization
The C-Series controller can automatically trigger an
equalization charge every 30 days. The status LED will
indicate that the equalization process is occurring.
The equalization process will continue until the voltage has
been held above the bulk setting for a cumulative period of
two hours. This might take several days on larger systems
with big batteries and small PV arrays. The battery voltage
only needs to exceed the bulk setting for the timer to start
counting–the voltage may not reach the equalization voltage
setting.
To enable automatic equalization, the jumper located on the
right side of the circuit board must be moved to the AUTO
setting. The default setting of the C-Series controller is for
manual equalization. To disable the automatic equalization
system, move the equalize jumper to MANUAL.

Manual Equalize

Auto Equalize

Figure 2-18 Auto Equalization Settings

Once a manual equalization has been triggered, the 30-day

period to the next automatic equalization will be restarted. To
prevent automatic equalization, move the equalize jumper to
the manual position.

Important: It is not recommended to use the Equalization

feature if the R46 Resistor is clipped.

32 975-0004-01-02 Rev D
 Temperature Compensation

Terminating the Equalization Process

To stop the equalization process, press the reset switch on the
right side of the unit until the status LED stops alternating
between red and green.
If the equalization process was shorter than one hour, the
controller will continue with a bulk charge cycle and then
hold the battery at the bulk setting for one hour (the
absorption stage) before returning to the float setting.

Front Panel LED

(flashes red/green
during equalization)

Press Reset
Switch until LED
stops alternating
between red and
green

Figure 2-19 Terminating the Equalization Charge

Temperature Compensation
Important: If using the C-Series as a DC Load Controller:
• Do NOT compensate the settings.
• Do not install the Battery Temperature Sensor.
For optimal battery charging, the Bulk and Float charge rates
should be adjusted according to the temperature of the
battery. When battery charging voltages are compensated
based on temperature, the charge voltage will vary depending
on the temperature around the batteries.

975-0004-01-02 Rev D 33
Installation

Temperature Compensation Based on Battery Type

The C-Series controller uses the battery type to determine the
temperature compensated voltage settings. The temperature
compensated charging voltage is normally based on a Lead –
Acid types of battery.
If using Alkaline-type batteries, the R46 resistor on the
circuit board inside the controller will have been clipped as
shown in “Setting Voltage Parameters for Alkaline Batteries”
on page 26. If the R46 resistor is cut, the temperature
compensation charging voltage will be based on
Alkaline-type batteries.
See the battery type below to determine the temperature
compensation value change per temperature or refer to the
temperature compensation calculations for a Lead-Acid type
battery as show in Table 2-2.
• Lead-Acid Type Batteries:
5 mV per cell per degree Celsius
• Alkaline -Type Batteries (NiCad or NiFe):
2 mV per cell per degree Celsius
Table 2-2 describes approximately how much the voltage
may vary depending on the temperature of the batteries.

Automatic Battery Temperature Compensation

Temperature compensation can be accomplished
automatically by using a Battery Temperature Sensor (BTS).
The sensor attaches directly to the side of one of the batteries
in the bank and provides precise battery temperature
information.
See “Installing the Battery Temperature Sensor” on page 51
for detailed instructions on how and where to install the BTS.
If a BTS is installed, the charge controlling process will be
automatically adjusted for the battery temperature. When
using a BTS, set the Bulk and Float voltage for a battery at
normal room temperature for 77 °F (25 °C).

34 975-0004-01-02 Rev D
 Temperature Compensation

Table 2-2 Variances in Charging Voltage based on Battery Temperature

Temperature
(around the BTS) 12-volt units 24-volt units 48-volt units

Lead Lead Lead

Acid NiCad Acid NiCad Acid NiCad
Celsius Fahrenheit (6 cells) (10 cells) (12 cells) (20 cells) (24 cells) (40 cells)
60 140 -1.05 -0.70 -2.10 -1.40 -4.20 -2.80
55 131 -0.90 -0.60 -1.80 -1.20 -3.60 -2.40
50 122 -0.75 -0.50 -1.50 -1.00 -3.00 -2.00
45 113 -0.60 -0.40 -1.20 -0.80 -2.40 -1.60
40 104 -0.45 -0.30 -0.90 -0.60 -1.80 -1.20
35 95 -0.30 -0.20 -0.60 -0.40 -1.20 -0.80
30 86 -0.15 -0.10 -0.30 -0.20 -0.60 -0.40
25 77 0.00 0.00 0.00 0.00 0.00 0.00
20 68 0.15 0.10 0.30 0.20 0.60 0.40
15 59 0.30 0.20 0.60 0.40 1.20 0.80
10 50 0.45 0.30 0.90 0.60 1.80 1.20
5 41 0.60 0.40 1.20 0.80 2.40 1.60
0 32 0.75 0.50 1.50 1.00 3.00 2.00
-5 23 0.90 0.60 1.80 1.20 3.60 2.40
-10 14 1.05 1.20 2.10 1.40 4.20 2.80
-15 5 1.20 0.80 2.40 1.60 4.80 3.20
-20 -4 1.35 1.40 2.70 1.80 5.40 3.60
-25 -13 1.50 1.00 3.00 2.00 6.00 4.00
-30 -22 1.65 1.10 3.30 2.20 6.60 4.40
-35 -31 1.80 1.20 3.60 2.40 7.20 4.80
-40 -40 1.95 1.30 3.90 2.60 7.80 5.20

975-0004-01-02 Rev D 35
Installation

If using a BTS, when the battery temperature drops below

77°F (25 °C), the regulation voltage setting automatically
increases. When the temperature rises above 77°F (25 °C) the
regulation battery voltage setting automatically decreases.

Manual Battery Temperature Compensation

If no Battery Temperature Sensor (BTS) is installed and the
batteries will be operating in very hot or very cold conditions,
adjust the bulk and float settings to allow for the battery
temperature.
The recommended adjustments can be made following Table
2-2. The setting should be lowered for ambient temperatures
above 86 °F (30 °C) and raised for ambient temperature
below 68 °F (20 °C).
If significant seasonal variations are common, you will have
to change the settings several times a year to prevent battery
damage and ensure proper operation.

Important: If the wiring to the sensor is damaged and the

wires are shorted or cut, the system will return to the
non-temperature compensated settings.

36 975-0004-01-02 Rev D
 Grounding

Grounding
The C-Series controller is designed to work with both
negative ground and ungrounded electrical systems. The
metal chassis of this charge/load controller must be grounded
for either system by connecting it with a copper wire to a
grounding electrode such as a ground rod driven into the
earth.
If a negative ground system is desired, connect the negative
current carrying conductor to the grounding system at one
point in the system. Consult local and national electrical
codes for more information and any additional requirements.
Telecom applications often require a positive ground system.
The C-Series controller switches the PV+/LOAD+ terminal
with the BATTERY POSITIVE (+) terminal. These terminals
must be kept separate. You can ONLY ground the battery
positive lead in this case, if your local jurisdiction allows it.

This symbol represents a

Safety (Earth) Ground.

Chassis Ground Lug

Figure 2-20 Grounding the C-Series Chassis

WARNING: Shock Hazard

Do not disconnect the chassis ground if loads are engaged.

975-0004-01-02 Rev D 37
Installation

Wiring
Important: Installations should meet all local codes and
standards. Installations of this equipment should only be
performed by skilled personnel such as qualified electricians and
Certified Renewable Energy (RE) System Installers. For a list of
Xantrex Certified RE dealers, please visit our website at
www.XantrexREdealers.com.

WARNING: Shock Hazard

Disconnect battery and PV sources before wiring.

CAUTION: Damage to Batteries

Ensure the voltage selection jumper is set properly before
energizing the system. Incorrect settings may result in damage to
the system as charging regulation will not occur.

DC Terminal Connector Locations

Terminal connectors for DC wiring are located on the lower
edge of the circuit board. See Figure 2-21.

Important: Regardless of the configuration, only the positive

conductor from a PV array OR a DC load may be connected to
the terminal marked “PV+/LOAD+”.
The common negatives can be reversed or wired with an
appropriately sized single conductor to a more convenient
location such as a DC load center negative bus, if necessary.
The shunt used to measure the current flow in the C-Series
controller is located in the positive conductor of the circuit
allowing greater flexibility in system grounding. The
negative terminals are all common to one another.

38 975-0004-01-02 Rev D
 Wiring

Terminal Torque Requirements

Once the wires have been installed, torque the terminals as
follows. Be careful not to overtighten.
• 20 inch-pounds for #14-10 AWG wire
• 25 inch-pounds for #8 AWG wire
• 35 inch-pounds for #6 AWG wire

Battery PV+/Load+ Negatives Negatives

Positive (+)
Common to each other

Figure 2-21 DC Connection Terminals

Wire Size and Over-current Protection Requirements

The wiring, over-current protection devices (fuses and circuit
breakers), and installation methods used must conform to all
national and local electrical code requirements.
Wiring should be protected from physical damage with
conduit or a strain relief clamp. You should pull the
temperature sensor cable through the conduit first as the
connector may not fit if other wires have been pulled first.

Current Rating
Each model of the C-Series controller is rated for a maximum
continuous current of 35, 40 or 60 amps. Since PV outputs
can vary due to the array size or sunlight striking it, the safe
minimum wire size should be based on the maximum current
ratings.

975-0004-01-02 Rev D 39
Installation

Minimum Recommended Wire Gauge

The minimum recommended wire gauge is:
• C35 and C40 Models:
#8 AWG with a 75 °C (167 °F) insulation rating
• C60 Models:
#6 AWG, with a 90 °C (194 °F) insulation rating
The terminals on the C-Series will accept up to #2 AWG
(33.6 mm2) copper or aluminum wire. However, UL
specifications only allow the use of up to #6 AWG
(13.3 mm2) maximum.
No crimp-on terminals or lugs are required.

Size 14 12 10 8 6 4 3 2
Diameter .073 .072 .115 .146 .184 .235 .281 .295

Size 1 1/0 2/0 3/0 4/0

Diameter .335 .380 .420 .475 .530

Figure 2-22 AWG Wire Gauge Reference Chart

Important: Figure 2-22 is for reference only. Sizes shown are

for the conductor. Do not include any insulation when
determining your wire size. Due to printing anomalies, these
dimensions may not be to scale.

Surge Protection
Since PV arrays are often mounted on an elevated structure
and thus are more susceptible to lightning strikes, protection
from lightning-induced power surges and other transient
power disturbances between the PV array and the C-Series

40 975-0004-01-02 Rev D
 Wiring

controller are strongly recommended. Put a surge protection

device on the input line of the C-Series controller between
the PV array and the controller.
If the battery, is over 15 feet away from the controller, or if it
is routed next to other wiring or sources of power, additional
surge protection devices are recommended. Put the surge
protection device for this scenario on the battery input line
between the battery and the controller.

Over-current Protection
The NEC requires conductors and over-current devices be
operated at no more than 80% of their rating. Refer to Table
2-3 for a listing of the minimum wire size and over-current
device ratings to be used for each model.
As a minimum, a 60-amp DC-rated current-limiting fuse or
circuit breaker should be installed near the battery for
protection from short circuits. To meet NEC requirements,
use a 60 amp circuit breaker listed for 100% duty for the C60.
To meet UL requirements, use #6 AWG copper wires rated
for 90 °C (194 °F) for the C60. Over-current protection for
the battery circuit is to be provided by others. Refer to
Table 2-3 for the correct ratings of the fuse and circuit
breaker.

Table 2-3 Minimum Wire Size

Controller Minimum Wire Size Over-Current Device Rating
C35 #8 AWG 45 amps
C40 #8 AWG 50 amps

C60a #6 AWG (90 °C/194 °F wire) 60 amps (listed 100% duty)

C60 #4 AWG b (75 °C/167 °F wire) 60 amps (listed 100% duty)

a.To meet UL requirements, use #6 AWG, (90 °C/194 °F) wire and a 60 amp Listed 100%
duty over-current device for the C60 controller.
b.Not approved by UL for direct connection into the controller. Use a splicer block and #6
AWG (90 °C/194 °F) wire to connect to the controller terminals.

975-0004-01-02 Rev D 41
Installation

Long-distance wire runs

If there is a significant distance between the PV array and the
controller and/or the controller and the battery, larger wires
can be used to reduce the voltage drop and improve
performance. Refer to Table 2-4.
To use a larger size wire, use a splicer block (terminal block)
intended for this purpose. This allows the larger cable size
from the batteries to be “spliced” to the smaller wire size
connected to the controller. Split-bolt kerneys can also be
used for wire splices.
Follow manufactures recommendations for torque and
mounting (if required). Splicer blocks and split-bolt kerneys
are available from renewable energy suppliers.

Maximum One-way Distance and Wire Size

Important: NEC Article 690 and local electrical codes should

be consulted for wire sizing and any additional installation
requirements.
• For a C60 use a 60 amp, 100% Continuous Duty breaker and
#6 AWG, 90 °C wire.
• Larger wire sizes may be used to improve performance, but
are NOT approved by UL to be installed in the controller. Use
a splicer block as previously described.

Refer to Table 2-4 and find your maximum current in the left
column, and the one-way distance from your power source
(feet/meters) to the C-Series controller (or the distance from
the C-Series controller to your load) on the same line, then
read the wire size required at the top of the column.

42 975-0004-01-02 Rev D
 Wiring

Table 2-4 One-Way Wire Distance and Wire Size

Maximum One-way Wire Distance for a < 3% Voltage drop
12 Vdc Application Shown
For 24 Vdc Systems, Multiply distance by 2
For 48 Vdc Systems, Multiply distance by 4

Distance in Feet (meters) Distance in Feet (Meters)a

12 10 8 6 4 3 2 1 1/0 2/0
Amps
AWG AWG AWG AWG AWG AWG AWG AWG AWG AWG

10 8.8 ft. 14 ft. 22.2 ft. 35.3 ft. 56.1 ft. 70.9 ft. 89.6 ft. 112.5 ft. 141.7 ft. 225.8 ft.
(2.68 m) (4.27 m) (6.77 m) (10.76 m) (17.10 m) (21.61 m) (27.31 m) (34.29 m) (43.19 m) (68.82 m)

12 7.3 ft. 11.6 ft. 18.5 ft. 29.4 ft. 46.7 ft. 59.1 ft. 74.6 ft. 93.7 ft. 118.1 ft. 188.2 ft.
(2.23 m) (3.54 m) (5.64 m) (8.96 m) (14.23 m) (18.01 m) (22.74 m) (28.56 m) (36.00 m) (57.36 m)

14 6.3 ft. 10 ft. 15.9 ft. 25.2 ft. 40.1 ft. 50.6 ft. 64.0 ft. 80.4 ft. 101.2 ft. 161.3 ft.
(1.92 m) (3.05 m) (4.85 m) (7.68 m) (12.22 m) (15.42 m) (19.51 m) (24.51 m) (30.85 m) (49.16 m)

16 5.5 ft. 8.7 ft. 13.9 ft. 22.1 ft. 35.0 ft. 44.3 ft. 56.0 ft. 70.3 ft. 88.6 ft. 141.2 ft.
(1.68 m) (2.65 m) (4.24 m) (6.74 m) (10.67 m) (13.50 m) (17.07 m) (21.43 m) (27.01 m) (43.04 m)

18 4.9 ft. 8.8 ft. 12.4 ft. 19.6 ft. 31.2 ft. 39.4 ft. 49.8 ft. 62.5 ft. 78.7 ft. 125.5 ft.
(1.49 m) (2.38 m) (3.78 m) (5.97 m) (9.51 m) (12.01 m) (15.18 m) (19.05 m) (23.99 m) (38.25 m)

20 4.4 ft. 7 ft. 11.1 ft. 17.6 ft. 28.0 ft. 35.4 ft. 44.8 ft. 56.2 ft. 70.9 ft. 112.9 ft.
(1.34 m) (2.13 m) (3.38 m) (5.36 m) (8.53 m) (10.79 m) (13.66 m) (17.13 m) (21.61m) (34.41 m)

25 5.6 ft. 8.9 ft. 14.1 ft. 22.4 ft. 28.3 ft. 35.8 ft. 45.0 ft. 56.7 ft. 90.3 ft.
(1.71 m) (2.71 m) (4.30 m) (6.83 m) (8.63 m) (10.91 m) (13.72 m) (17.28 m) (27.52 m)

30 4.7 ft. 7.4 ft. 11.8 ft. 18.7 ft. 23.6 ft. 29.9 ft. 37.5 ft. 47.2 ft. 75.3 ft.
(1.43 m) (2.26 m) (3.60 m) (5.70 m) (7.19 m) (9.11 m) (11.43 m) (14.39 m) (22.95 m)

35 6.4 ft. 10.1 ft. 16.0 ft. 20.2 ft. 25.6 ft. 32.1 ft. 40.5 ft. 64.5 ft.
(1.95 m) (3.08 m) (4.88 m) (6.16 m) (7.80 m) 9.78 m) (12.34 m) (19.66 m)

40 5.6 ft. 8.8 ft. 14.0 ft. 17.7 ft. 22.4 ft. 28.1 ft. 35.4 ft. 56.5 ft.
(1.71 m) (2.68 m) (4.27 m) (5.39 m) (6.83 m) (8.56 m) (10.79 m) (17.22 m)

45 7.8 ft. 12.5 ft. 15.7 ft. 19.9 ft. 25.0 ft. 31.5 ft. 50.2 ft.
(2.38 m) (3.81 m) (4.79 m) (6.07 m) (7.62 m) (9.60 m) (15.30 m)

50 7.1 ft. 11.2 ft. 14.2 ft. 17.9 ft. 22.5 ft. 28.3 ft. 45.2 ft.
(2.16 m) (3.41 m) (4.33 m) (5.46 m) (6.86 m) (8.63 m) (13.78 m)

60 6.3 ft. 9.3 ft. 11.8 ft. 14.9 ft. 18.7 ft. 23.6 ft. 37.6 ft.
(1.92 m) (2.83 m) (3.60 m) (4.54 m) (5.7 m) (7.19 m) (11.5 m)

a.These wire sizes are not approved by UL to be installed in the controller, but may be used
externally of the controller (using a splicer block) to reduce voltage drop and improve
performance.

975-0004-01-02 Rev D 43
Installation

PV Charge Control Mode Wiring

The procedure below is illustrated in Figure 2-23.

WARNING: Shock Hazard

PV arrays generate voltage whenever light strikes the surface of the
array. Before connecting the C-Series controller, cover or
disconnect the array to prevent any current from being generated.
To connect the C-Series controller as a charge controller:
1. Connect the PV array’s positive (+) output to the PV
array disconnect.
2. Route another (+) cable from the other end of the RE
disconnect to the PV GFP.
3. Route another (+) cable from the same switch in the PV
GFP to the terminal marked PV POS/LOAD in the C-Series
controller.
4. Connect the PV array’s negative (–) output to the
terminal marked COMMON NEGATIVES.
5. Connect another negative (-) cable from the other
COMMON NEGATIVES to the Negative bus in the DC
disconnect.
6. Route a negative (–) wire from the PV GFP to the
Negative bus in the DC disconnect.
7. Connect a positive (+) cable from terminal marked BAT
POS to the battery disconnect in the DC disconnect.
8. Connect a second positive (+) cable to the other side of
the battery disconnect in the DC disconnect and connect
to the positive (+) battery terminal.
9. Connect the negative (–) battery cable to the negative bus
in the DC disconnect and tighten the lugs.
10. Tighten per torque requirements outlined on page 39.
Allow a little slack on the cables within the controller and
secure the wiring with strain reliefs.

44 975-0004-01-02 Rev D
 Wiring

Common
Battery PV+ Array Battery PV Array Negatives
Positive (+) Positive (+) Negative (–) Negative (–)

4
3

7
5
1

2
6

8 A
9

A Ensure the proper grounding is in

place for the entire system.

Figure 2-23 PV Charge Control Mode Wiring

975-0004-01-02 Rev D 45
Installation

Diversion Control Mode Wiring

The procedure below is illustrated in Figure 2-24.
When using the C-Series unit as a Diversion or DC Load
Controller, the DC load needs to be connected to the
controller terminals marked as PV +/LOAD+ and COMMON
NEGATIVE.
To connect the C-Series as a diversion load controller:
1. Connect your DC current source (PV, wind, hydro, etc.)
directly to the RE disconnect.
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.
4. Connect a cable from controller terminal marked BAT
POS to the battery disconnect.
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.
7. Connect a cable from the controller’s other terminal
marked COMMON NEGATIVES to the negative terminal of
your DC diversion load.
8. Connect a cable from the controller’s terminal marked
PV+/LOAD+ to the positive terminal of your DC
diversion load.
9. Tighten per torque requirements outlined on page 39.
Allow a little slack on the cables within the controller and
secure the wiring with strain reliefs.

Important: Do not use light bulbs for diversion loads. Use

only resistive loads such as air- or water-cooled heating elements

46 975-0004-01-02 Rev D
 Wiring

Common
Negatives
Battery Diversion Load Battery Diversion Load
Positive (+) Positive (+) Negative (–) Negative (–)

4 8 6 7

3
5

A Ensure the proper grounding is in

place for the entire system.

Figure 2-24 Diversion Control Mode Wiring

975-0004-01-02 Rev D 47
Installation

DC Load Control Mode Wiring

The procedure below is illustrated in Figure 2-25.
To connect the C-Series controller as a DC load
controller:
1. Connect a cable from the BAT POSITIVE terminal on the
controller to a battery disconnect.
2. Connect the positive battery cable to the battery
disconnect.
3. Connect the negative battery cable to the one of the
terminals marked COMMON NEGATIVES.
4. Connect a cable between the PV POS/LOAD terminal on
the controller and the positive terminal on the DC load.
5. Connect a cable between the controller’s other COMMON
NEGATIVES terminal and to the negative terminal of the
load.
6. Tighten per torque requirements outlined on page 39.
Allow a little slack on the cables within the controller and
secure the wiring with strain reliefs.

48 975-0004-01-02 Rev D
 Wiring

Common
Negatives
Battery DC Load Battery DC Load
Positive (+) Positive (+) Negative (–) Negative (–)

1 3

Figure 2-25 Load Control Mode Wiring

975-0004-01-02 Rev D 49
Installation

Installing Optional Accessories

The following sections describe how to install the optional
accessories available for the C-Series Multifunction DC
Controller.

Installing a Digital Display

Follow the instructions in the C-Series Meter Displays
Installation Guide for preparing the CM or CM/R for
installation.
The display will connect to the controller at the RJ-15 port on
the lower left corner of the circuit board.

Important: Ensure the voltage jumpers on the back of the CM

or CM/R match the system voltage as configured inside the
controller unit. See the C-Series Meter Displays Installation
Guide for additional information.

Digital Meter Display Port

RJ-15 Port
C-Series Circuit Board

Serial Communication Cable

Figure 2-26 Installing a Digital Display

50 975-0004-01-02 Rev D
 Installing Optional Accessories

Installing the Battery Temperature Sensor

To install the BTS:
1. Install the BTS on the side of the battery below the
electrolyte level. It is best to place the sensor between
batteries and place the batteries in an insulated box to
reduce the influence of the ambient temperature outside
the battery enclosure.
2. Insert the RJ-11 plug on the other end of the BTS into the
BTS Port on the lower right corner of the circuit board
inside the C-Series controller.

Important: Ventilate the battery box at the highest point

to prevent hydrogen accumulation.

Battery Temperature Sensor Port

RJ-11 Port
C-Series Circuit Board

Figure 2-27 Installing the BTS

975-0004-01-02 Rev D 51
Installation

Reinstalling the Faceplate

To reinstall the faceplace on the C-Series controller:
1. Align faceplate with front of chassis so that screw holes
in the corners line up.
2. Insert the phillips screws into the screw holes and
tighten.

Align these screw holes.

Replace the phillips screws
to secure the faceplate.

Figure 2-28 Re-installing the CM Faceplate

52 975-0004-01-02 Rev D
3 Operation

Chapter 3 contains information about the operation of a

C-Series Multifunction DC Controller.

For Information on: See:

“Basic Operation” page 54
“LED Status Indicator” page 55
“Charge Control or Diversion Control page 56
Indications (Green)”
“Load Control Indications (Red)” page 58
“Error Mode Indication (Orange)” page 59
“Reconnecting to Loads” page 60
Operation

Basic Operation
The C-Series controller (all models) has one multicolor LED
status indicator and one reset button.

Reset Switch
(on side of unit)

Multicolor LED
indicator

Reset Switch

Figure 3-1 C-Series Status LED and Reset Button Location

54 975-0004-01-02 Rev D
 LED Status Indicator

LED Status Indicator

The multicolor LED on the base unit, or the optional CM
faceplate or CM/R remote, indicates the operating status of
the controller. A color-coded label is included on the cover of
the controller explaining the status LED’s indications.
• When in Charge Control mode, the LED will be green.
• When in Load Control mode, the LED will be red.
• When an Error Condition exists or the load has
disconnected, the LED will be orange.
• When battery equalization is in process, the LED
alternates between red and green.

Important: The green and red color of the LED only indicates
the particular operating mode and the battery voltage level. It
does not indicate whether the charging source is functioning
properly

Multicolor LED indicator

STATUS Green Blink Charge Control Mode

Green Solid Battery Charged
Red Blink Load Control Mode
Red Solid Battery Discharged
Orange Blink Slow Load Disconnected
Orange Blink Fast Overload/Overtemp
Red / Green Alternating - Equalization Enabled

C35 35 Amp Controller 12/24 VDC

C40 40 Amp Controller 12/24/48 VDC
C60 60 Amp Controller 12/24 VDC

Charge / Load Controller

5916-195th STREET NE ARLINGTON WASHINGTON 98223 TELEPHONE(360)435-8826 FAX(360)435-2229

Figure 3-2 C-Series Front Panel Label

975-0004-01-02 Rev D 55
Operation

Table 3-1 Battery Voltage LED Indicators

Green LED LED Red LED
(Charge/Diversion Mode) Status (Load Control Mode)
Battery at FLOAT Setting Always Battery at LVD Setting
ON (for 6 minutes = LVD)

Battery at BULK Setting 5 blinks > 0.15 >0.03 >0.45

above above above
LVD LVD LVD

BULK Setting Minus (–) LVD Setting Plus (+)

0.25 Vdc 0.50 Vdc 1.00 Vdc 4 blinks 0.15 Vdc 0.30 Vdc 0.45 Vdc
0.50 Vdc 1.00 Vdc 2.00 Vdc 3 blinks 0.30 Vdc 0.60 Vdc 0.90 Vdc
0.75 Vdc 1.50 Vdc 3.00 Vdc 2 blinks 0.45 Vdc 0.90 Vdc 1.35 Vdc
> 0.75 > 1.50 > 3.00 1 blink > 0.45 > 0.90 > 1.375
below Bulk below Bulk below Bulk below Bulk below Bulk below Bulk
12 volts 24 volts 48 volts DC 12 volts 24 volts 48 volts
Voltage

Charge Control or Diversion Control Indications

(Green)
The flashing rate of the LED indicates the controller’s stage
of operation and approximate battery voltage.
• One to four flashes indicates the controller is in the Bulk
stage. As the flashing rate increases, the batteries are
progressively closer to the Bulk voltage. Table 3-1
indicates the approximate level the battery is below the
Bulk setting.
• Five flashes indicates the controller has reached Bulk
voltage and is in the Absorption stage.
• Solid green means the controller is in the Float stage and
is regulated at the Float voltage.

56 975-0004-01-02 Rev D
 LED Status Indicator

For example, if the system battery voltage is 24 volts and the

internal Bulk voltage setting is set for 28 volts, you can
estimate how much below the Bulk setting the batteries are
by subtracting the number in Table 3-1 (the internal Bulk
setting).
With the LED indicating three blinks, the battery voltage is
approximately 27 volts (28 volts Bulk setting minus
1.00 volts in the table).
With the LED indicating one blink, the battery voltage is
somewhere below 26.5 volts (28 volts Bulk setting minus
>1.50 volts in the table).

Important: LED will light green only in Diversion and Charge

Control mode (unless it is reinstalled backwards).

Blinking Green
The controller is in the Charge Control or Diversion Control
mode and the battery is not fully charged. As the battery
voltage approaches the BULK setting, the status LED will
blink green several times (up to five) and then pause,
indicating the battery voltage is approaching the bulk setting
and provides an indication of the battery condition. Refer to
Table 3-1 to determine the battery voltage.

Important: A single green flash indicates the battery is well

below the bulk voltage setting. It does NOT indicate the batteries
are charging or their state-of-charge.

Solid Green
The battery is being charged in the FLOAT stage. The status
LED remains ON solid unless the batteries drop below the
float voltage setting for an accumulative period of one hour.
This allows the user to confirm that the system reached the
float stage during the charging process when checked at the
end of the day. Reaching the float stage frequently is a good
indication of proper system operation and will maximize
battery life and performance.

975-0004-01-02 Rev D 57
Operation

Equalization Mode Indication (Red/green)

Be sure to read all cautions and warning regarding
equalization charging batteries BEFORE allowing an
equalization charge to occur. Damage to batteries can occur.

Alternating Red and Green

The controller is in the EQUALIZE mode.
It will automatically stop the equalization process after
accumulating two hours of operation at a voltage above the
BULK setting.
The user can manually stop the equalization process at any
time by pressing the reset switch until the status LED stops
alternating red and green.

Load Control Indications (Red)

The flashing rate of the LED indicates the controller’s stage
of operation and approximate battery voltage.

Blinking Red
As battery voltage approaches the LVD setting, the LED will
blink red several times (up to five) and then pause providing
an indication of battery voltage. Refer to Table 3-1 to
determine the battery voltage.

Solid Red
The controller is in the Load Control mode and the battery
voltage has reached the Low Voltage Disconnect (LVD)
setting. After a 6-minute delay, DC loads will be
disconnected unless the user reduces the loads to a point that
the battery voltage exceeds the LVD setting.

58 975-0004-01-02 Rev D
 LED Status Indicator

Error Mode Indication (Orange)

The C-Series Multifunction DC Controller error modes
include the following.
• Over-temperature Condition - fast flash
• Over-current Condition - fast flash
• Low-Voltage Disconnect Condition (Load Control
Mode) - slow flash

Over-temperature Condition
The temperature of the controller’s transistors is continuously
monitored. This protects the charge controller from damage
in high temperature environments. If excessive temperatures
are detected while operating in Charge or Diversion Control
mode, the controller’s transistors are rapidly turned off and
on to reduce the charge rate. This will reduce the transistor
temperature.
In Load Control mode, the load is disconnected before the
transistors reach an excessive temperature. Once the
temperature has dropped, the loads are reconnected.

Over-Current Condition
During operation, the C-Series controller continuously
monitors the current flowing through it. If the current exceeds
85 amps, the transistor switches are opened, stopping the
flow of electricity. The detection circuitry is faster than
breakers or fuses, and they will not trip or blow when a fault
occurs.
The C-Series controller automatically resets the over-current
protection system every 6 minutes. If an overload or short
circuit is still present, the controller will shut off and wait
another 6 minutes. This will occur continuously until the
problem is corrected.

975-0004-01-02 Rev D 59
Operation

Fast Blinking Orange

When the over-current or over-temperature protection system
has caused the controller to shutdown, the status LED will be
orange and will blink fast (about once a second).

Low-voltage Disconnect Condition

If voltage remains below the LVD setting, the unit will
disconnect after a 6-minute “delay” (or “grace”) period. To
reset and reconnect for another “grace” period
(approximately 6 minutes), press and release the reset switch.
The user can press the reset switch for a maximum 10-minute
“grace” period, or can wait until the voltage rises above the
Low Voltage Reconnect (LVR) setting to allow an automatic
reset to occur if the EQ/LVR (Auto) jumper is set to
“AUTO”.

Slow Blinking Orange

When the disconnect/reconnect system has been activated,
the LED will slowly blink orange. The controller is in the DC
Load Control mode and has disconnected the loads due to
reaching the LVD setting.

Reconnecting to Loads
To reconnect the loads, press the reset button on the right side
of the unit. If the voltage is below the LVR level, the DC load
can be reconnected for approximately 6 minutes.
A delay up to five seconds may occur before the controller
attempts to restart after pressing the reset switch.
Multiple reconnects are allowed, but the “on” time duration
will vary with battery voltage. The EQUALIZE jumper
allows the controller to be set for AUTO reconnect of the DC
load when the voltage exceeds the LVR setting.

60 975-0004-01-02 Rev D
 Reset Switch

Important: The LED will light red only in Load Control

mode; never in Charge or Diversion mode (unless it is reversed
upon reinstallation).

Reset Switch
Use the Reset Switch on the side of the chassis for the
following conditions.
• To manually initiate battery equalization in Charge
Control mode, press and hold the Reset Switch until the
red and green LED start to flash.
• To manually suspend battery equalization in Charge
Control mode, press and hold the Reset Switch until the
red and green LED stop flashing.
• To reset following an error condition, press and release
the Reset Switch.
• To reset following a low-voltage disconnect, press and
release the Reset Switch.
See “Reconnecting to Loads” for additional information
about reconnecting to loads.

Reset Switch

Figure 3-3 Reset Switch

975-0004-01-02 Rev D 61
62
4 Troubleshooting

Chapter 4, “Troubleshooting” contains information

about identifying and resolving possible problems with
systems using a C-Series Multifunction DC Controller.

For Information on: See:

“PV Charge Control Troubleshooting” page 64
“Diversion Control Troubleshooting” page 66
“Load Control Troubleshooting” page 68
Troubleshooting

PV Charge Control Troubleshooting

The following table lists possible problems that may arise
when using the C-Series Multifunction DC Controller as a
PV Charge Controller.

Table 4-1 PV Charge Control Problems

Problem Possible Cause Solution
Controller is PV positive and Verify the voltage on PV
overcharging battery Battery positive wires terminal and Battery
(verified by measured have been swapped. terminal are from the
current through the correct sources.
controller).
Controller is locking up. PV positive and Verify the voltage on PV
Battery positive wires terminal and Battery
have been swapped. terminal are from the
correct sources.
Status LED Blinks PV wires are Verify PV polarity relative
Orange after switching connected in reverse to battery negative.
on array breaker. polarity.
Status LED Blinks A. Controller is A. Check ambient air
Orange at times during overheating. temperature around
the solar day. B. Array is supplying controller.
more current than the B. Divide array with
controller is rated for. another controller or use
(Press reset button and larger controller.
measure current).

64 975-0004-01-02 Rev D
 PV Charge Control Troubleshooting

Table 4-1 PV Charge Control Problems

Problem Possible Cause Solution
Current uneven between A. Solar arrays are A. Check array output.
multiple controllers. supplying different B. Set controllers to the
amounts of current to same settings.
each charge controller. C. Check wiring.
B. Charging set points D. Try a different
are not all set the same. controller if metering is
C. Excess voltage drop unacceptable.
in wiring causing
controllers to measure
the battery voltage
differently and regulate
accordingly.
D. Accuracy of the
controllers may vary
between controllers,
due to tolerances in
meter design.
Status LED blinks red LED may have been Remove LED and install
while mode jumper is in reinstalled backwards. correctly. “Flat side” of
“charge control” but still LED should be on left
regulates normally. side.
Battery voltage is BTS is compensating Nothing - Intended
exceeding Bulk and charging voltages operation. See
Float settings in cold based on battery “Temperature
weather and not temperature. Compensation” on
reaching settings in hot page 33.
weather.

975-0004-01-02 Rev D 65
Troubleshooting

Diversion Control Troubleshooting

The following table lists possible problems that may arise
when using the C-Series Multifunction DC Controller as a
Diversion Controller.

Table 4-2 Diversion Control Problems

Problem Possible Cause Solution
Status LED Blinks Diversion load draws Measure the current the
Orange after switching too much current diversion load draws when
on diversion load (above controller battery voltage is applied
breaker or when rating). across it.
diversion begins (Bulk Note: A diversion load
or Float settings with an acceptable “hot”
reached). current may have an
excessively high inrush
current that can cause the
controller to overcurrent.
Caution: Do not test
without a circuit breaker in
circuit.
Battery voltage is A. BTS is A. Nothing - Intended
exceeding Bulk or Float compensating charging operation. See
settings. voltages based on “Temperature
battery temperature. Compensation” on
B. Diversion load is page 33.
too small for output of B. Measure the current the
charging source(s). diversion load draws when
battery voltage is applied
across it. Caution: Do not
test without a circuit
breaker in circuit.
A larger diversion load or
additional controller each
with their own diversion
loads may be necessary.

66 975-0004-01-02 Rev D
 Diversion Control Troubleshooting

Table 4-2 Diversion Control Problems

Problem Possible Cause Solution
Diversion load operates Bulk Voltage setting on A. Bulk voltage on
while a generator (fuel diversion controller is controller needs to be set
powered) is running. set too close to other higher than other charging
charger settings. sources or use a
switch/relay to disable the
diversion load while using
a generator.
Diversion load operates Mode jumper is set for Change jumper setting.
immediately at full “Load Control” instead
power when load of “Charge Control”.
breaker is turned on.

975-0004-01-02 Rev D 67
Troubleshooting

Load Control Troubleshooting

The following table lists possible problems that may arise
when using the C-Series Multifunction DC Controller as a
Load Controller.

Table 4-3 Load Control Problems

Problem Possible Cause Solution
Load disconnects at A. Load Control decal A. Install the decal or
different point than set is not in place. follow procedure in
for. B. BTS has been manual. See “Setting
installed. Voltage Parameters for
Load Control Mode” on
page 24.
B. Battery Temperature
Sensors should not be used
in load control
applications.
Status LED Blinks Startup or Inrush Use larger controller or
Orange after switching current exceeds “buffer” the controller by
on the load breaker. controller rating. using a relay/contactor
where the controller
operates only the coil of
the relay/contactor and not
directly to the DC load.

68 975-0004-01-02 Rev D
A Specifications

Appendix A, “Specifications” provide the specifications

for the C-Series Multifunction DC Controller.

For information on: See:

“Electrical Specifications” page 70
“Features and Options Specifications” page 71
“Environmental Specifications” page 72
Specifications

Electrical Specifications
The following lists the electrical specifications for the
C-Series controllers Models C35, C40, and C60.

Table A-1 Electrical Specifications

Model C35 C40 C60
Voltage 12 Vdc 24 Vdc 12 Vdc 24 Vdc 48 Vdc 12 Vdc 24 Vdc
Configuration

Maximum PV 55 Vdc 55 Vdc 125 Vdc 125 Vdc 125 Vdc 55 Vdc 55 Vdc
Array Open
Circuit Voltage

Charging Load 35 amps DC 40 amps DC continuous 60 amps DC

Current continuous continuous

Recommended 60 amps DC 60 amps DC 60 amps DC

Breaker Size with #6 AWG #6 AWG (100% continuous
recommended duty cycle),
Wire Size in #6 AWG
Conduit (90 ° C rated)

Maximum Short 85 amps 85 amps intermittently 85 amps

Circuit Current intermittently intermittently

Maximum Voltage 0.30 volts - charge control mode

Drop

Total Current While operating - 15 mA (typical), at idle - 3 mA (tare)

Consumption

Charger Regulation Solid state, 3-stage (bulk, absorption and float) Pulse Width Modulation
Method (PWM)

Charging Control Settings:

Lead Acid Battery 12 Volt System: 24 Volt System: 48 Volt System:

Float 12.5 - 14.5 Vdc Float 25.0 - 29.0 Vdc Float 50.0 - 58.0 Vdc
Bulk 13.0 - 15.0 Vdc Bulk 26.0 - 30.0 Vdc Bulk 52.0 - 60.0 Vdc
EQ = +1 above Bulk EQ = +2 above Bulk EQ = +4 above Bulk

NiCad battery 12 Volt System: 24 Volt System: 48 Volt System:

Float 14.5 - 16.5 Vdc Float 29.0 - 33.0 Vdc Float 58.0 - 66.0 Vdc
Bulk 15.0 - 17.0 Vdc Bulk 30.0 - 34.0 Vdc Bulk 60.0 - 68.0 Vdc
EQ = not EQ = not recommended EQ = not
recommended recommended

70 975-0004-01-02 Rev D
 Features and Options Specifications

Table A-1 Electrical Specifications

Model C35 C40 C60
Load Control Settings:

System Voltage: 12 Volt System: 24 Volt System: 48 Volt System:

Low Voltage
Reconnect LVR 12.0 to 14.0 Vdc LVR 24.0 to 28.0 Vdc LVR 48.0 to 56.0 Vdc
Low Voltage
Disconnect LVD 10.5 to 12.5 Vdc LVD 21.0 to 25.0 Vdc LVD 42.0 to 50.0 Vdc

Features and Options Specifications

The following lists the features and options specifications for
the C-Series controllers Models C35, C40, and C60.

Table A-2 Features and Options Specifications

Model C35 C40 C60
Standard Features

Status Indicator Multi color LED indicates the operating/battery voltage status.

Low Voltage Disconnect User selectable manual or automatic reconnection - includes warning
Load Control Mode flash before disconnect and 6 minutes “grace” period.

Equalization Charge User selectable manual or automatic equalization (every 30 days).

Charge Control Mode

Short Circuit Protection Fully electronically protected with auto-reset.

Adjustable Control Two user-adjustable, voltage setpoints for control of loads or charging
Setpoints (test points sources (settings retained if battery is disconnected.)
provided for high
accuracy

Options

LCD Meter Panel Back-lit, 32-character, alpha-numeric liquid crystal display panel for
(CM, CM/R-50, remote (CM/R) or front mounting (CM) on the C-Series controller.
CM/R-100)
External Battery Provides automatic adjustment of the charge control set point to the
Temperature Sensor battery temperature (may be extended)
(BTS/15, BTS/35)

975-0004-01-02 Rev D 71
Specifications

Environmental Specifications
The following lists the environmental specifications for the
C-Series controllers Models C35, C40, and C60.

Table A-3 Environmental Specifications

Model C35 C40 C60
Enclosure Type Indoor, ventilated, powder-coated steel with 3/4" and 1" knockouts.
Operating 32 to 104 °F (0 to +40 °C)
Temperature Range Specifications at 25°C

Non-operating -67 to 284 °F (-55 to +75 °C)

Temperature Specifications at 25°C

Altitude Limit 15,000 feet (5,000 meters)

(operating)

Altitude Limit 50,000 feet (16,000meters)

(non-operating)

Dimensions 8" x 5" x 2.5" 10" x 5" x 2.5"

(H x W x D) (20.3 cm x 12.7 cm x 6.35 cm) (25.4 cm x 1.7 cm x 6.35 cm)
Mounting Vertical Wall Mount

Weight (Controller 2.5 lbs (1.2 kg) 3.0 lbs (1.4 kg) 3.0 lbs (1.4 kg)
only)

Weight (Shipping) 3.0 lbs (1.4 kg) 3.5 lbs (1.6 g) 3.5 lbs (1.6 kg)

*Specifications at 25°C

Specifications subject to change without notice

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B Batteries

Appendix B, “Batteries” describes types of batteries.

For information on: See:

“Battery Types” page 74
“Battery Sizing” page 76
“Equalization Charging” page 77
Batteries

Battery Types
Batteries come in different sizes, types, amp-hour capacity,
voltages and chemistries. Here are a few guidelines that will
help in battery selection, and ensure that the batteries are
properly maintained. The best source of the most appropriate
settings for the C-Series will be from the manufacturer or
supplier of the batteries.

WARNING: Explosion/Corrosion Hazard

Batteries can vent hydrogen-sulfide gas, which is corrosive to
electronic equipment. Batteries also generate hydrogen and oxygen
gas that can explode when exposed to a spark. Be sure to read the
safety precautions on page viii regarding batteries.

Automotive Batteries
Automotive and truck batteries are designed for high
cranking power – not deep-cycling. Do not use them unless
no other battery type is available. They simply will not last
long in a cycling application.

Maintenance-Free Batteries
This type of battery is often sold as a RV or marine battery,
but is rarely appropriate for use with a PV system. They
typically have an additional reserve of electrolyte, but are
vented. This is not the same as a sealed battery.

Deep-Cycle Batteries
Best suited for use with PV systems, this type of battery is
designed to be more deeply discharged before being
recharged. Deep-cycle batteries are available in many sizes
and types. The most common is the vented liquid electrolyte
battery.

74 975-0004-01-02 Rev D
 Battery Types

Vented batteries usually have battery caps. The caps may

appear to be sealed, but are not. The caps should be removed
periodically to check the level of electrolyte. When a cell is
low, distilled water should be added after the battery is fully
charged. If the level is extremely low, add only enough
distilled water to cover the plates before recharging. The
electrolyte volume increases during the charging process and
the battery will overflow if it is filled all of the way up before
recharging. Use only distilled water because impurities will
reduce battery performance.
A popular and inexpensive deep-cycle battery is the “golf
cart” battery. It is a 6-volt design, typically rated at
220 amp hours. RV and marine deep-cycle batteries are also
popular for small systems. They are usually referred to as
Group 24 or Group 27 batteries and are rated at 80 to 100
amp-hours at 12 volts. Many larger systems use L16
batteries, which are usually rated at 350 amp-hours at 6-volts
each. They are 17 inches high and weigh about 130 pounds.
8D batteries are available with either cranking or deep-cycle
construction. Purchase only the deep-cycle version. The 8D is
typically rated at 220 amp hours at 12 volts.

Sealed Batteries
Another type of battery construction is the sealed gel cell.
They do not use battery caps. The electrolyte is in the form of
a gel rather than a liquid, which allows the batteries to be
mounted in any position. The advantages are no maintenance,
long life (800 cycles claimed) and low self-discharge.
Absorbed glass mat (AGM) electrolyte batteries are also
acceptable. Their electrolyte is contained in mats between the
battery plates.
Sealed batteries reduce the maintenance requirements for the
system and are good for remote applications. They are much
more sensitive to the charging process and can be ruined in as
little as a day of overcharging.

975-0004-01-02 Rev D 75
Batteries

NiCad and NiFe Batteries

The Xantrex C-Series is compatible with NiCad
(nickel-cadmium) NiFe (nickel-iron) and alkaline-type
batteries, which must be charged to a higher voltage level to
achieve a full charge.
To use the C-Series with NiCad batteries, clip the wire on the
resistor labeled “R46” in the middle of the C-Series circuit
board by cutting it. See “Setting Voltage Parameters for
Alkaline Batteries” on page 26 for instructions on how to clip
this wire.
Avoid damage to neighboring components.

Important: In all applications the BULK voltage setting

should be adjusted to a level below the maximum operating
voltage of the DC loads. This may be as low as 15 volts for some
types of electronic loads. Undercharging may occur in this
instance, but DC equipment will be protected. Check with the
manufacturers of the DC equipment being powered for its
maximum DC input voltage tolerance. If equalization is expected
to occur, then the DC equipment being used must tolerate the
voltages which will occur during the equalization process.

Battery Sizing
Batteries are the fuel tank of the system. The larger the
batteries, the longer the system can operate before recharging
is necessary. An undersized battery bank results in short
battery life and disappointing system performance.
To determine the proper battery bank size, compute the
number of amp-hours that will be used between charging
cycles. Once the required amp hours are known, size the
batteries at approximately twice this amount. Doubling the
expected amp-hour usage ensures that the batteries will not
be overly discharged and will extend battery life.

76 975-0004-01-02 Rev D
 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 77
Batteries

CAUTION: Damage to Batteries

Equalization should be done only on vented (not sealed or
maintenance-free) lead-acid, liquid-electrolyte batteries. The
battery manufacturer should be consulted before attempting to
equalize any other battery type. Add clean, distilled water to the
battery following the equalization process.

CAUTION: Damage to Loads

DC loads may need to be disconnected by turning off circuit
breakers or removing fuses before equalization to prevent damage
by the required higher voltages used in the equalization process.

CAUTION
If the batteries are equipped with hydro caps (catalytic gas
recombiner caps), they should be removed during the equalization
process. If hydro caps are used, you should disable automatic
equalization to prevent possible damage.

78 975-0004-01-02 Rev D
 Equalization Charging

Equalization Setpoints (Non-Sealed Batteries Only)

Table B-1 Typical Bulk and Float Setpoints for Batteries
Equalizing
Battery Type Bulk Volts Float Volts Charge
Default Settings (knobs 14.0 Vdc 13.5 Vdc Disabled
at nine o’clock position) (manual
jumper)
Sealed Gel Lead Acid 14.1 Vdc 13.6 Vdc Non
Battery recommended.
Consult Battery
manufacturer.
AGM Lead Acid 14.4 Vdc 13.4 Vdc Charge to
Battery 15.5 Vdc or per
manufacturer.
Maintenance-Free 14.4 Vdc 13.4 Vdc Limited
RV/Marine appropriateness
- if water level
can be checked.
Deep-Cycle, Liquid 14.6 Vdc 13.4 Vdc Charge to
Electrolyte Lead 15.5 Vdc or per
Antimony Battery battery
manufacturer.
NiCad or NiFe Alkaline 16.0 Vdc 14.5 Vdc Not
Batterya recommended.
Consult battery
manufacturer.
Values shown are for 12-volt systems. For 24-volt Systems, multiply this
setting shown by 2. For 48-volt systems, multiply the settings shown by 4.

Important: The following settings (Table B-1) are guidelines only. Refer to
your battery vendor for specific settings and battery maintenance guidelines.
a.For NiCad and NiFe batteries, you must clip the R46 resistor and add 2 volts to the values
for BULK AND FLOAT shown on the circuit board. For example, set the BULK for
16.0 V adjust the BULK knob to 14.0 V after clipping R46. Values above are for batteries
at room temperature. For applications with significant temperature variations or systems
with sealed batteries, install a battery temperature sensor.

975-0004-01-02 Rev D 79
80
C Diversion Loads

Appendix C, “Diversion Loads” provides additional

information about Diversion Loads.

For information on: See:

“Diversion Load Types” page 82
Diversion Loads

Diversion Load Types

Several different types of diversion loads are available to the
alternative energy market. These loads are designed to
operate with the power output levels common to most
diversion load controllers. The following are several
available diversion loads which may be used successfully for
heating water or air.
A 120 Vac, 2000-watt water heater element, available at most
hardware stores, may be used with a 12-, 24-, or 48-volt DC
system; however do not expect a 2000-watt power
dissipation. The power draw is determined by the heater
element’s DC resistance, the output voltage of the controller,
as well as the output current capability of the charging
source(s).
These heater elements were designed to operate at
120 volts AC. A 48-volt, 40-amp charge controller will
operate just fine with this type of a system providing about
500 watts of power dissipation.
A 12- or 24-volt diversion load controller will work but
doesn’t put out enough power to effectively heat water with
only one element. The remedy to this type of problem is to
parallel several of these heater elements to increase the power
output.
Table C-1 below shows power dissipation of a 120 Vac,
2000-watt heater element operated at different voltages. Note
that the voltages given are roughly the bulk charge stage
voltages for a given system.

Table C-1 Power Dissipation

System Voltage Power Amperage
60 Vdc (48 Vdc system) 500 W 8.3 amps
30 Vdc (24 Vdc system) 125 W 4.2 amps
15 Vdc (12 Vdc system) 31 W 2.1 amps
120 Vac 2000 W 16.7 amps

82 975-0004-01-02 Rev D
 Diversion Load Types

Regardless of the type of diversion load you decide to utilize,

make sure that the diversion load can handle all the power the
charging system is capable of putting out. Paralleling heater
elements (whether open air or water heater) will allow more
power dissipation.
A good rule of thumb is to not have a combined charging
source greater than 80% of the diversion load controller’s
current handling ability.
For example, if a Xantrex C-Series, 40-amp diversion load
controller is being used, do not place a combination of
charging sources which are capable of putting out more than
32 amps (80% of 40 amps) on the load controller’s circuit.
Sizing a diversion system this way allows a safety margin for
unusual conditions (high winds, high water flow, etc.).
It is not recommended that light bulbs be used as diversion
loads for a couple of reasons:
1. An incandescent light bulb has a substantially lower cold
filament resistance than when it is on. This means it
draws more power (up to five times) to start the light
when it is cold than once the filament has warmed up.
Even a 40-watt light bulb may have an in-rush amperage
at turn-on of 200 amps. This could cause the load
controller to shut down.
2. In the event a light bulb load burns out, a
smaller-than-necessary load will be present, and the
excess energy will have nowhere to go.

975-0004-01-02 Rev D 83
84
Warranty and Product
Information

Warranty
What does this warranty cover? This Limited Warranty is provided by Xantrex
Technology, Inc. ("Xantrex") and covers defects in workmanship and materials in your C-
Series Multifunction DC Controller. This warranty period lasts for two years from the date
of purchase at the point of sale to you, the original end user customer. You require proof of
purchase to make warranty claims.
This Limited Warranty is transferable to subsequent owners but only for the unexpired
portion of the Warranty Period. Subsequent owners also require proof of purchase.
What will Xantrex do? Xantrex will, at its option, repair or replace the defective product
free of charge, provided that you notify Xantrex of the product defect within the Warranty
Period, and provided that Xantrex through inspection establishes the existence of such a
defect and that it is covered by this Limited Warranty.
Xantrex will, at its option, use new and/or reconditioned parts in performing warranty
repair and building replacement products. Xantrex reserves the right to use parts or
products of original or improved design in the repair or replacement. If Xantrex repairs or
replaces a product, its warranty continues for the remaining portion of the original
Warranty Period or 90 days from the date of the return shipment to the customer,
whichever is greater. All replaced products and all parts removed from repaired products
become the property of Xantrex.
Xantrex covers both parts and labor necessary to repair the product, and return shipment to
the customer via a Xantrex-selected non-expedited surface freight within the contiguous
United States and Canada. Alaska and Hawaii are excluded. Contact Xantrex Customer
Service for details on freight policy for return shipments outside of the contiguous United
States and Canada.
How do you get service?If your product requires troubleshooting or warranty service,
contact your merchant. If you are unable to contact your merchant, or the merchant is
unable to provide service, contact Xantrex directly at:

Telephone: 1 800 670 0707 (toll free North America)

1 360 925 5097 (direct)
Fax: 1 800 994 7828 (toll free North America)
1 360 925 5143 (direct)
Email: [email protected]

85
Warranty and Product Information

Direct returns may be performed according to the Xantrex Return Material Authorization
Policy described in your product manual. For some products, Xantrex maintains a network
of regional Authorized Service Centers. Call Xantrex or check our website to see if your
product can be repaired at one of these facilities.
What proof of purchase is required?In any warranty claim, dated proof of purchase
must accompany the product and the product must not have been disassembled or
modified without prior written authorization by Xantrex.
Proof of purchase may be in any one of the following forms:
• The dated purchase receipt from the original purchase of the product at point of sale to
the end user, or
• The dated dealer invoice or purchase receipt showing original equipment
manufacturer (OEM) status, or
• The dated invoice or purchase receipt showing the product exchanged under warranty
What does this warranty not cover?This Limited Warranty does not cover normal wear
and tear of the product or costs related to the removal, installation, or troubleshooting of
the customer's electrical systems. This warranty does not apply to and Xantrex will not be
responsible for any defect in or damage to:
a) the product if it has been misused, neglected, improperly installed, physically
damaged or altered, either internally or externally, or damaged from improper use or
use in an unsuitable environment;
b) the product if it has been subjected to fire, water, generalized corrosion, biological
infestations, or input voltage that creates operating conditions beyond the maximum or
minimum limits listed in the Xantrex product specifications including high input volt-
age from generators and lightning strikes;
c) the product if repairs have been done to it other than by Xantrex or its authorized ser-
vice centers (hereafter "ASCs");
d) the product if it is used as a component part of a product expressly warranted by
another manufacturer;
e) the product if its original identification (trade-mark, serial number) markings have
been defaced, altered, or removed.

Disclaimer
Product
THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY
XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE
PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS,
GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND LIABILITIES, EXPRESS OR
IMPLIED, STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT,
HOWEVER ARISING (WHETHER BY CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF
MANUFACTURER'S LIABILITY, OPERATION OF LAW, CONDUCT, STATEMENT OR
OTHERWISE), INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR
CONDITION OF QUALITY, MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

86 975-0004-01-02 Rev D
 Return Material Authorization Policy
PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO
APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD
STIPULATED UNDER THIS LIMITED WARRANTY.
IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, DIRECT, INDIRECT,
INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES, COSTS OR EXPENSES
HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT
RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO
PROPERTY, ANY PERSONAL INJURY, ANY DAMAGE OR INJURY ARISING FROM OR AS
A RESULT OF MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION, INTEGRATION
OR OPERATION OF THE PRODUCT.

Exclusions
If this product is a consumer product, federal law does not allow an exclusion of implied
warranties. To the extent you are entitled to implied warranties under federal law, to the
extent permitted by applicable law they are limited to the duration of this Limited
Warranty. Some states and provinces do not allow limitations or exclusions on implied
warranties or on the duration of an implied warranty or on the limitation or exclusion of
incidental or consequential damages, so the above limitation(s) or exclusion(s) may not
apply to you. This Limited Warranty gives you specific legal rights. You may have other
rights which may vary from state to state or province to province.

Warning: Limitations On Use

Please refer to your product manual for limitations on uses of the product.
SPECIFICALLY, PLEASE NOTE THAT THE C-SERIES MULTIFUNCTION DC
CONTROLLER SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS
OR OTHER MEDICAL EQUIPMENT OR DEVICES. WITHOUT LIMITING THE GENERALITY
OF THE FOREGOING, XANTREX MAKES NO REPRESENTATIONS OR WARRANTIES
REGARDING THE USE OF THE XANTREX C-SERIES MULTIFUNCTION DC
CONTROLLER IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL
EQUIPMENT OR DEVICES.

Return Material Authorization Policy

Before returning a product directly to Xantrex you must obtain a Return Material
Authorization (RMA) number and the correct factory "Ship To" address. Products must
also be shipped prepaid. Product shipments will be refused and returned at your expense if
they are unauthorized, returned without an RMA number clearly marked on the outside of
the shipping box, if they are shipped collect, or if they are shipped to the wrong location.
When you contact Xantrex to obtain service, please have your instruction manual ready
for reference and be prepared to supply:
• The serial number of your product
• Information about the installation and use of the unit
• Information about the failure and/or reason for the return
• A copy of your dated proof of purchase
Record these details in “Information About Your System” on page 89.

975-0004-01-02 Rev D 87
Warranty and Product Information

Return Procedure
1. Package the unit safely, preferably using the original box and packing materials.
Please ensure that your product is shipped fully insured in the original packaging or
equivalent. This warranty will not apply where the product is damaged due to
improper packaging.
2. Include the following:
• The RMA number supplied by Xantrex Technology, Inc. clearly marked on the
outside of the box.
• A return address where the unit can be shipped. Post office boxes are not
acceptable.
• A contact telephone number where you can be reached during work hours.
• A brief description of the problem.
3. Ship the unit prepaid to the address provided by your Xantrex customer service
representative.
If you are returning a product from outside of the USA or Canada In addition to the
above, you MUST include return freight funds and are fully responsible for all documents,
duties, tariffs, and deposits.
If you are returning a product to a Xantrex Authorized Service Center (ASC) A
Xantrex return material authorization (RMA) number is not required. However, you must
contact the ASC prior to returning the product or presenting the unit to verify any return
procedures that may apply to that particular facility.

Out of Warranty Service

If the warranty period for your C-Series Multifunction DC Controller has expired, if the
unit was damaged by misuse or incorrect installation, if other conditions of the warranty
have not been met, or if no dated proof of purchase is available, your inverter may be
serviced or replaced for a flat fee.
To return your C-Series Multifunction DC Controller for out of warranty service, contact
Xantrex Customer Service for a Return Material Authorization (RMA) number and follow
the other steps outlined in “Return Procedure” on page 88.
Payment options such as credit card or money order will be explained by the Customer
Service Representative. In cases where the minimum flat fee does not apply, as with
incomplete units or units with excessive damage, an additional fee will be charged. If
applicable, you will be contacted by Customer Service once your unit has been received.

88 975-0004-01-02 Rev D
 Information About Your System

Information About Your System

As soon as you open your C-Series Multifunction DC Controller package, record the
following information and be sure to keep your proof of purchase.

❐ Serial Number (on DC end) _______________________________

❐ Purchased From _______________________________

❐ Purchase Date _______________________________

If you need to contact Customer Service, please record the following details before
calling. This information will help our representatives give you better service.

❐ Type of installation [e.g. ______________________________

RV, truck, vehicle, home]

❐ Length of time inverter has ______________________________

been installed

❐ Battery/battery bank size ______________________________

❐ DC wiring size and length ______________________________

❐ Warning, Error or Panel ______________________________

Fault Message

❐ Appliances operating when ______________________________

problem occurred

❐ Description of problem ______________________________

____________________________________________________________

____________________________________________________________

975-0004-01-02 Rev D 89
90
Index
A I
Accessories 12 Information about Your System form
Automatic Equalization 32 89

B J
Battery Safety Information viii Jumper Settings 18
Battery Temperature Compensation 6
Battery Temperature Sensor 12, 51
BULK charge voltage 22
K
Knockouts 14

C L
Charge Control or Diversion Control
Mode Indications 59 LED Status Indicator 55
Customer Service Load Control Indications 57
preparing to call 89 Low Voltage Disconnect 25
Low Voltage Reconnect 24

D M
Diversion Control Mode 8, 26
Manual Equalization 31

E N
EQ/LVR Jumper 21
Equalization Charging 30 National Electrical Code 3
Equalization Mode Indication 57
Error Mode Indication 59 O
Operating Mode Jumper 20
F Over-Current 59
Over-Temperature 59
FLOAT charge voltage 23

G P
Grounding 37 Photovoltaic Charge Control Mode 7
proof of purchase 89
Pulse Width Modulated 2
purchase date 89
Index

R
Reset Switch 59

S
Safety Instructions vii
serial number 89

T
Test Points for Voltage Settings 28
Torque Requirements 39
Troublshooting 64

V
Voltage Jumper 20

W
warranty
out of warranty service 88
terms and conditions 85
Wire Size 39
Wiring 38

X
Xantrex
web site v

92 975-0004-01-02 Rev D
Xantrex Technology Inc.
1 800 670 0707 Tel toll free NA
1 360 925 5097 Tel direct
1 800 994 7828 Fax toll free NA
1 360 925 5143 Fax direct
[email protected]
www.xantrex.com

975-0004-01-02 Printed in China