Coleman Air C440-HVAD Manuel utilisateur

oleman

C440-HVAD

Digital Diversion Controller

•

Fully digital user interface.

• Solenoid based with 3-stage charge control.

• No jumpers or potentiometers need to be set.

• LCD 2 x 16 back-lit display.

• Both manual and automatic equalize modes are available.

• Dual shunts for monitoring both solar and turbine amperage and wattage.

• Automatic nominal battery voltage detection.

• Nearly all charge parameters can be managed through the user interface.

• Relay on time can be controlled and set for diversion times up to several hours.

• Upper and lower set points can both be set.

• Automatic LCD back light dimming to save energy.

• Dual Truck Star breakers, one each for your turbine input and diversion output.

• 12, 24 or 48-volt battery systems.

• Vented cover.

• Modular PCB Layout.

The C440-HVAD balances

the tried and true with the

newest technologies, resulting

in a super capable diversion

controller for your alternate

energy system that’s easy to

use and even easier to love.

Visit ColemanAir.us for the

most current information.

Quick Start:

All user settable parameters as well as additional information are accessible via the user

interface which consists of the LCD screen and the three buttons located on the front cover.

Pressing any key during the normal operation of the unit will cause the main menu to be

displayed. Depressing the right/left buttons will scroll through the menu options. Entering the

“Enter” button will cause that menu option or value to be selected. Use of the up/down menu

increases and decreases the current menu value. Pressing the up button exits the menu (unless

you are currently modifying a value, in which case it will increase the value. First press “Enter”

to select the current value, and then press the up button to exit the menu).

The Red LED on the front of the unit indicates an error of some nature. The exact cause of the

error will be shown on the LCD screen (unless you have activated one of the menu options).

The Green LED on the front cover is lighted when the unit is first turned on and also any time

the charge performance is considered high enough to complete the current charge cycle. If the

solar/turbine power is not adequate to complete the charge cycle, the cycle will be extended and

the mode timer will not count down. When this green LED is lighted, the charger is able to pass

enough current to the batteries to complete a full charge of the batteries.

The internal LED on the upper left of the large PCB board (motherboard) is lighted when the

solenoid is engaged.

The red LED on the small daughter board is lighted when there has been an over-voltage detected. To clear an over-

voltage condition, all power to the unit must be disconnected for at least 10 seconds. Once power is re-applied, the

unit should clear the fault. Over-voltage condition

s should be addressed by ensuring your wind turbine and/or

solar inputs never exceed 100 volts and both wind and solar are never enabled without first ensuring the controller

is powered up and running from the batteries.

The Coleman Air C440-HVAD can handle 12, 24 or 48-volt systems. When power is first

applied to the unit, the microprocessor analyzes the battery voltage and automatically determines

the battery bank nominal voltage. You do not need to set any jumpers or make any manual

selections; this is fully automatic.

More Features:

• Reverse polarity protected – This unit will not be damaged if you inadvertently reverse the battery sense lines.

• Over Voltage protection. The circuit board is protected against over voltage.

• Steel enclosure - with multiple conduit openings.

• Large terminals - that can actually terminate large wire.

• Pre-wired for both solar and wind. Super easy terminations and hookup. Saves hours of time and trouble not having

to interconnect all of these components.

•

Custom settings a

re saved.

The settings and parameters you enter are saved to eeprom incase of a power outage.

The HVAD Menu

is selected by pressing any button on the front panel. Pressing the right/left buttons will scroll

through the menu options at the current level. Pressing the “Enter” button will cause that menu option or value to be

selected and/or displayed. Use of the up/down menu increases and decreases the current menu value. Pressing the up

button exits the menu (unless you are currently modifying a value, in which case it will increase the value. First press

“Enter” to select the current value, and then press the up button to exit the menu).

For example: To change the float set point of the controller. Press the “Enter”, “Up/Down” or “Scroll” button on the

front panel. The Charge submenu will then be displayed. Press the “Enter” or “Down” button to enter the submenu.

Press the “Scroll” button towards the right two times. This will display the float set point along with the current value

of the set point. Press the “Up/Down” button to alter this value to the desired voltage. Press the “Enter” button to save

this value. Press the “Up/Down” button upwards to exit the menu system. You could also of course continue to alter

more values and/or view other settings.

Charge modes and set points:

As introduced above, the HVAD is fully configurable through the front panel buttons and display. There are no

jumpers that need to be set or potentiometers that need to be adjusted. All configurable options are reachable via the

menu system. This menu system is comprised of a main menu and several submenus as depicted above in the menu

layout graphic. Each submenu allows you to either set a particular value, view information, or perform specific

actions, like running a solenoid test or starting the equalize mode. Most of these menu items are self-explanatory and

will not be discussed in detail; however, there are some features and settings that deserve greater explanation.

First and foremost, you generally do not need to change anything. When the controller is first powered up, it

analyzes the current battery voltage to determine whether the battery bank is a 12, 24 or 48-volt bank. If your battery

bank nominal voltage has changed sine the last time the unit was powered up, then the microprocessor will reset all

values to the factory defaults and store the new information. These factory defaults are normally perfectly adequate

for a lead acid battery bank used with most solar and wind installations. Changes to the settings are therefore only

required when your requirements are different in one manner or another from what has been set by the factory. The

controller is basically plug-and-play! Factory defaults can be viewed in the technical specifications page in this

manual.

Although the HVAD is a solenoid-based “Diversion Controller”, it is capable of simulating a 3-stage charge controller

due to the fact that the controller can track both a bulk and float setting. The word simulating is used because no

solenoid or relay based controller can react to instantaneous changes of the battery voltage or limit the current flow in

the same manner as a PWM controller can. This said, the controller is a VERY capable mechanical controller that

does have the ability to track multiple voltages and react accordingly. Additional charging logic has also been added

including such features as re-bulking, an absorb mode that allows for automatic adjustments due to changes in solar

illumination (low current) as well as offering both a manual and automatic equalize. So, this is no stripped down

mechanical controller … but what is a 3-stage charge controller?

The main advantage to solid-state controllers and the very capable HVAD is that they offer more advanced charging

modes than single stage, i.e., mechanical controllers. We will briefly discuss the three stage charging modes.

•

Bulk Charge

•

Absorption Charge

•

Float Charge

The HVAD is capable of providing these 3 stages:

The 1

stage in a 3 stage charging mode is the Bulk Charge: In this mode, most (if not all) of the available current is

sent to the batteries to raise the battery voltage up to the bulk set point. This mode brings the battery to about 80% of

its capacity. Generally the bulk charge voltage is set to between 14 and 15 volts, with 14.4 volts often used as a

standard. There is really no perfect voltage setting here as there are many factors involved. The ambient temperature,

the size of the energy sources vs. the battery bank size, the desired length of time in this mode, the cost of the energy

(if it is supplemented by the grid or generator, etc.). Simply stated, the bulk charge gets the battery up to a mostly full

state at a quick but healthy rate.

The 2

stage of the 3 stage charging mode is the Absorption Charge: Once the bulk mode set point is reached, the

charger attempts to hold and track this value. The absorption mode uses the same set point as the bulk mode with the

difference being that the battery voltage is no longer rising up to the set point; but instead, it is being maintained at

that set point. Due to the chemical nature of the battery, this constant voltage causes the charge current to drop as the

battery reaches a “full” state of charge. The factory default for the absorption mode is set to 120 minutes, which under

sufficient solar/turbine energy input is ample to charge most battery banks.

The final stage is the Float Charge: This mode is the charge mode that the battery is under most of the time for a

properly designed system. Once the batteries are brought to a full state of charge, the float charge mode maintains the

batteries at a voltage level of around 13.2 to 13.7 volts (for a flooded, 12 volt lead acid battery. By applying the

required amount of charge current to offset any load the battery might be powering, as well as overcoming the

batteries natural self-discharge, the batteries longevity is greatly increased.

Another charge mode incorporated by many chargers (and the HVAD) is the equalize charge. This mode is not a part

of the normal charge cycle, but is instead initiated (either manually or automatically based on a timer) to help mix the

electrolytes of the battery. During normal use, the battery’s chemical mix becomes stratified. (Separated from top to

bottom). An equalize charge uses approximately 10 percent higher voltage to help mix these elements in the battery.

Equalize charging also helps bring all of the batteries in a multi-battery bank to an equal state. Most people agree that

an equalize charge should be run once every 10 to 40 days, for 2 to 16 hours. During this charge cycle quite a lot of

gassing will occur, which causes the fluids to be mixed and the plates to be "cleaned". An equalize charge is not

recommended for sealed batteries.

The HVAD also incorporates a “ReBulk” set point. Should the battery voltage drop to the “ReBulk” set point for

more than a few seconds, the controller will exit the current charge mode and start a new bulk mode. If the Bulk

mode is already active, then the controller will restart the countdown timer to force a new full-length bulk mode

charge.

The HVAD incorporates the 3 stage algorithm discussed here with the some limitations that are due to the fact that the

controller uses a mechanical switch. The primary limitation is the number of times per minute the solenoid can be

switched on and off without damage or premature failure to the solenoid. This limits the controller in systems that

have small battery banks and high current charge sources. When such a condition exists, the controller will not be

able to react as quickly as a solid-state controller and may allow the voltage to rise or fall further than optimal. To

alleviate this condition, it is recommended that your charge source(s) not exceed the battery bank’s amp-hour capacity

by more than four times. That is, this controller is best suited to a system where the combined solar/wind energy is

not capable of fully charging the battery bank faster than 4 hours. Higher current sources will tend to whip the

voltages up and down, with a loss of efficiency. A PWM or MPPT controller would be a better choice in this

environment. That said, the HVAD is very suitable for systems that incorporate larger wind turbines and/or smaller

solar systems that are properly matched to their battery bank.

The HVAD excels when used in conjunction with a wind/hydro turbine to run diversion loads.

The HVAD is a diversion controller by design. A diversion controller is very well suited to wind and hydro systems

in that these energy sources need (or should) stay connected to the battery at all times, whereas solar can be

disconnected without problems. The HVAD takes “diversion” to a new level by incorporating the 3 stages, equalize,

configurable cycle times and many features not seen before in a diversion controller. The following section will

explain some of the settable features that allow the HVAD to excel as a diversion controller yet is used as a solar

disconnect controller as well.

1. Setting up the charge parameters. See the technical specifications pages for the factory defaults. If you

need to alter any charge settings, simply select the charge menu choice from the main menu and scroll though

the submenu to select and alter the values. There are very few limits placed on the values you set, other than

you cannot set a float set point higher than the bulk, or the bulk higher than double the battery system voltage

etc. Once you set or reset these settings, you should monitor the controller and see that these settings are

working to achieve the results you require.

The factory time setting for the absorption is 120 minutes. This value can be changed as required. This

timer is performance based. The microprocessor uses multiple algorithms to determine if during the last

minute the batteries actually realized a certain level of charging. The main consideration is whether the

controller was able to reach and hold the upper set point. If the performance during the last minute for the

absorb mode is considered adequate, the timer will be decremented by one minute. If on the other hand, the

performance is below the standard, the timer will not be decremented, which can result in a charge cycle that

lasts much longer to ensure the batteries actually receive the best charge possible in less than optimal charging

conditions.

The green LED on the front cover will be lighted when the processor determines the performance is

high and off when the performance is not high enough to properly charge the batteries. This allows you to

quickly visualize the real time charging performance that the controller is detecting. Often the green LED will

blink on and off randomly and rapidly as the solar/wind energy fluctuates.

2. Turning on or off the Equalize mode. By default, the equalize mode is not enabled. To start a manual

equalize, select the Equalize submenu, scroll right or left to the “Start Equalize?”. When this submenu is

displayed, press the “Up/Down” button to select “YES” and then press the “Enter” button to request this mode.

The equalize mode will then be queued. The controller will not actually start the equalize mode until the bulk

set point has been reached. Once the mode is started, the countdown timer will start and the mode will stay in

affect until the timer expires. The length of time in this mode is controlled by the “Equalize Minutes” submenu

option. The equalize mode is not performance based and will not be restarted automatically due to low current

conditions.

The automatic equalize: Changing the Equalize days from “0” to any number up to 90 will enable this

feature. The equalize function will then run once the day timer has been triggered and the bulk set point has

been achieved. The equalize will not actually start if the bulk set point is not achievable via the solar/turbine

charge inputs.

3. The Advanced Menu. The factory settings for the HVAD are to engage and disengage the solenoid as soon

as the currently active set point (bulk, float, equalize), is reached and to allow the battery voltage to drop by no

more than 6% from that setting. In addition, the microprocessor will attempt to track these set points as much

as possible but will not allow an enabled state of the solenoid of less than two seconds. Given these settings,

the controller may turn on and off the solenoid several times per minute. This is great if you want to keep the

batteries as close to the set point as possible, but not suitable if the primary purpose of the controller is to run a

pump, grid tied inverter, perhaps even Bitcoin mining equipment or any other real world load that needs to be

engaged for a longer period of time in order to be useful. This is where the advanced menu is used.

a) The relay offset setting: This setting allows you to specifically set the “lower set point” for any mode

based on a percentage of the upper set point. For example. The factory setting for this value is 6% and

the factory set point for the bulk mode in a 12-volt system is 14.4 volts. Given these two values, the

upper set point will be 14.4 volts and the lower set point will be a drop of 6% (or 94% of the upper set

point), yielding a lower set point of 13.4 volts. This means that the solenoid will be enabled when the

battery voltage rises to 14.4 volts and disabled when the battery bank drops to 13.4 volts. These upper

and lower voltages will cycle back and forth as the solenoid is engaged and disengaged; providing

there is adequate charge current to raise the battery voltage to the upper trip point. This distance

between the upper and lower trip point is called hysteresis and is necessary in a solenoid-based

controller. The hys-ter-e-sis width can be narrowed (the lower set point is brought upwards) by

lowering the relay-offset percentage. In the same manner, a higher percentage will yield a lower low

set point. The lower the set point, the longer the solenoid will stay engaged waiting for the battery to

drop. This setting alone can often be used to control a pump or similar device, where you desire to run

the load as long as the batteries are not depleted past a certain point.

b) The Minimum relay on time. This 2

advanced solenoid parameter allows setting a minimum enable

time of the solenoid from 2 seconds up to many minutes. This setting can therefore allow a particular

load to be turned on for a minimum of, for example, 10 minutes, without regard to the lower set point.

During this time, the microprocessor still monitors the battery bank and will exit this timer if the

battery drops considerably and is considered by the controller to be depleted. The processor, based on

the bulk set point you have entered, automatically calculates this depleted value set point to protect (as

much as possible) the battery from an over-discharge.

Please note: A lead-acid battery’s life is greatly reduced when the level of discharge is quite deep or the

battery is allowed to enter into a “dead battery” state. You should familiarize yourself with the parameters

for your particular battery before setting these advanced parameters.

4. The View Submenu: The view menu allows you to view the real time voltage and amperage of the connected

solar and or turbine energy sources. The controller incorporates two shunts, allowing it to measure both solar

and turbine amperages simultaneously. This feature is new to the HVAD, whereas previous controllers were

only able to display the amperage for a single input.

Note: If you do not utilize both wind and turbine inputs, it is possible (perhaps likely), that there will be a

small amount of current that is displayed for the unused input. For instance, if you are using only the solar

input, the controller may sense a few tenths of an amp on the turbine input. This is normal as there are stray

currents in any system where large amperages are involved.

Please note these very important electrical concepts: When the solenoid is not enabled, the solar panels are

effectively wired directly to the batteries through the normally closed contacts of the solenoid, just as if you

had hooked the positive of the solar panel directly to the positive of the battery bank. This means that the solar

voltage and the battery voltage will be identical at that time. The solar panels will move the voltage of the

batteries up and the batteries will have moved the solar panel voltage down until they reach an equilibrium

based on ohms law. This means, the controller cannot report the VOC (voltage open circuit) of the solar panel

input when it is connected to the batteries. The solar VOC reading will only be accurate when the solenoid is

enabled! Hint: Run the test cycle to watch how the enable/disable of the solenoid affects the solar voltage.

This same concept applies to the turbine input; however, the turbine input is never disconnected from the

batteries, therefore the turbine voltage is always identical to the battery voltage and therefore it is not reported

separately by the controller.

Another concept to understand is that the solar voltage will always be the same as the battery (and turbine)

voltage when you do not have an active solar input. This seems impossible, yet due to the same fact that the

solar input is tied to the battery positive via the normally closed contacts of the solenoid, the controller will

“see” the battery voltage on the solar input, with no way to determine if it is battery voltage or solar voltage.

When the solenoid is enabled, the solar voltage will be “floating” (it is not connected to anything) without an

active input and may not be considered accurate at that time, as there can be stray inductances present.

Essentially, if you do not have any solar hooked up, then just ignore any voltage readings the controller may

display for the solar input.

The current reading (amperage) of the solar and turbine inputs will be zero (or very close to zero), if there is no

active input for that source. When the solenoid is enabled, the solar current will drop to zero. When the

solenoid is not enabled, the solar input will be at its maximum. Both turbine and solar amperage readings

should always be accurate within a few percent, regardless of the active inputs (solar only, turbine only, or

both active). Voltages can be misleading due to the concepts discussed above, so using amperages is the key

to determining the performance of the inputs.

Other Menus and Submenus:

In addition to changing the charging parameters, the menu system can be used to view the maximum voltages and

amperages reached during the active charge cycle. These values are reset each time the charge mode is changed (a

change from the bulk mode to the absorb mode for example). They are also reset when the controller is powered up.

These values can be helpful in determining the performance of the charging sources.

Another submenu option is the “Start Test?” feature. To select this feature, press any button on the front panel,

scroll right or left to the Diagnostics menu, press the down button to select the “Start Test?” feature. Press the

“Up/Down” button either direction until “YES” is displayed, then press “Enter”. The controller will now enable and

disable the solenoid 5 times, using two-second intervals. During this time, the battery voltage, solar voltage, solar

amperage and turbine amperage will be displayed in an alternating and repeating pattern that allows you to see each of

these values during both the enabled and disabled state of the solenoid. As discussed above, if you have an active

solar input, you would expect to see the solar amperage at its maximum when the solenoid is disabled and at zero

when the solenoid is enabled. The voltage for the solar input should read the same as the battery voltage when the

solenoid is not enabled, but rise to the VOC of the solar panels when the solenoid is enabled.

During the test, all LEDs on the front cover will be lighted when the solenoid is enabled and off when the solenoid is

disabled. The green LED on the upper left of the main circuit board (motherboard) inside the controller will also be

cycled on and off during the test.

The turbine amperage

(see bullets below)

will not change substantially during the cycling of the solenoid since the solenoid

does not connect or disconnect the turbine input from the battery.

A few exemptions to monitor during the test:

•

If you have a large diversion load connected to the controller, then the turbine amperage may increase when

the solenoid is engaged due to the fact that the turbine will now be connected to both the battery and diversion

load, allowing more current to flow from the turbine. This is normal.

•

If the solenoid contacts are defective, then you may hear the solenoid’s coil pull in (as normal), but see no

difference in the solar amperage or solar voltage during the test. This generally indicates the normally closed

contacts of the solenoid are not actually closing and opening, but instead staying connected or disconnected.

Please note, there is a possibility that there is no active solar input, so be sure that during the time the

solenoid is not enabled, you see the VOC of the solar panels. This value is normally 1.5 – 2 times the

battery voltage.

•

Should the solenoid not enable or disable during the test, then the solenoid’s coil may be defective. There is

also the possibility that the main circuit board is not proving enough current to the solenoid. Check that the

green LED on the upper left of the motherboard is cycled on and off during the test. With a voltmeter, check

that there is at least 10 volts on the coil (top two smaller terminals) of the solenoid, when the solenoid is

engaged. (Use caution not to touch other components with your meter leads or fingers.)

•

The solenoid cannot be properly controlled if your battery voltage is very low (less than 10.5 volts). So

running a test during a low voltage condition may not render useful information.

If during the test, you determine the solenoid contacts have failed or the solenoid cannot be engaged and you have

verified that the controller is powered up with a sufficient amount of power (at least 10.5 volts) and have verified that

all solar and turbine inputs are normal, then replacing the solenoid is indicated. Refer to the Replacing the Solenoid

section in the later part of this manual for further instruction.

Resetting to factory defaults:

If for any reason you wish to start over with all configuration settings and parameters, then simply select the “Reset

Defaults?” submenu, choose “YES”, then press “Enter”. All configuration settings will be reset to the factory

defaults. This reset is also performed anytime the batteries nominal voltage (12, 24 or 48-volt) changes from the last

time the unit was powered up. This means if you change your battery bank from a 12-volt system to a 48-volt system,

then the microprocessor will automatically initiate a reset to factory defaults for the currently detected battery bank.

About load diversion:

The basic operating philosophy of a diversion controller is quite simple. Monitor the battery voltage, and if it should

rise to a predetermined level, connect a diversion load or “Dummy Load”, of sufficient size, to the battery or energy

source to prevent the battery voltage from increasing any further. This is a very simple, yet very effective way of

preventing battery overcharging. All alternate energy systems should have some form of battery overcharge

protection.

Several schools of thought on the subject.

1. The source of power (wind turbine, solar panels etc.) -- should remain connected to the batteries while the

dump load controller is actively dumping the excess voltage.

2. The source should be diverted to the load directly and disconnected from the batteries.

We happen to believe that is far better to leave the wind turbine connected to the batteries at all times. Why?

When you remove the battery from a wind turbine and send it's power directly to a load, then it sees for all

practical purposes a short circuit (depending on the resistance of the load and lead wires.) This may cause the

turbine blades to slow dramatically and in some cases bring it to a halt. This braking action can cause heat

build up in the stator if it is repeated every few seconds or so (if the battery is just a little over the top). When

you allow the turbine to see the batteries, along with the load, the turbine remains more within its design

realm -- always a good thing.

Please note: this controller does not include a blocking diode or an A/C to D/C rectifier, as these are specific to your

application. If you are using the controller with a DC turbine or solar panels, you may need to purchase a blocking

diode. A/C turbines require rectification from A/C to D/C.

FAQ: Do I need a diversion load for a wind turbine?

Yes. Diversion controllers work by diverting excess energy from the wind turbine to a diversion or “dummy load”.

This diversion allows the turbine to remain under a load at all times. A solar panel may be safely disconnected from

the batteries, but an active wind turbine should never be disconnected from its load (battery/diversion load). When a

wind turbine is not loaded, it can easily speed out of control in high wind events, which can lead to catastrophic failure

of the turbine as well as the possibility of damage and injury to other property and people. It is very important that

your turbine has a very reliable load at all times.

Please see our FAQs located on our website, www.ColemanAir.us for more information on this subject and

many others.

Diversion Load Types

A diversion load needs to be larger (by at least 10-20%), than the sum total of all your solar/wind/hydro charge

sources combined that will be routed through the diversion load. When the diversion load is too small, battery voltage

may continue to rise even when the diversion is active. It is also important to use a load that is not likely to fail. Light

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