Parts. WindyNation s 40 to 120 AMP Diversion Charge Controller Wiring Diagram (copyright 2009) 40 AMP Relay. Enclosure Charge Controller

Transcription

1 WindyNation s 40 to 120 AMP Diversion Charge Controller Wiring Diagram (copyright 2009) Parts 1 AMP fuse fuse holder Enclosure Charge Controller fuse fuse holder Female spade connectors Terminal connectors (Use to connect the generator and dummy load to your battery)

2 Step 1 : Connecting the charge controller to the battery (2) Connect the red wire coming out of the charge controller to the 1 AMP fuse holder. Make sure the fuse has been removed! (2) 1 AMP Fuse Charge Controller (1) With the fuse REMOVED, connect the 1 AMP fuse holder to the positive () terminal of the battery (1) (3) (3) Connect the black wire coming out of the charge controller to the negative () terminal of the battery. Battery

3 Step 2 : Connecting the charge controller to the relay Charge Controller Pin # 86 Pin # 85 (1) (2) (1) Locate the white wire coming out of the charge controller. Connect the female spade connector on the white wire coming out of the charge controller to Pin # 86 of the relay. (2) Locate the yellow wire coming out of the charge controller. Connect the female spade connector on the yellow wire coming out of the charge controller to Pin # 85 of the relay.

4 Step 3 : Connecting the relay to the battery (1) Connect Pin # 87 (NOT PIN # 87a) on the 40 AMP relay to the battery positive terminal using the supplied insulated female spade connector. Use appropriately sized wire for this connection. This wire needs to be rated to handle the power produced by your generator (solar panel, wind generator or hydrogenerator). Note: The wire to make this connection is not supplied. You must use your own wire. The female spade terminal is supplied. (1) Battery

5 Step 4 : Connecting the diversion load to the battery and 40 AMP relay (1) Diversion Load (1) Connect Pin # 87a on the 40 AMP relay to the diversion load positive terminal using the supplied female spade connector. The wire must be rated to handle the power of your diversion load. (2) Connect the diversion load negative to the negative terminal on the battery. The wire must be rated to handle the power of your diversion load. (2) Battery Note: The wire to make these connections is not supplied. You must use your own wire.

6 Step 5 : Connecting the generator ground to the battery DC Wind Turbine (1) Connect the negative terminal(s) of your power generation source(s) to the negative terminal on the battery. Make certain that the wire can handle the power created by your power generation source(s). Note: Power generation sources = solar panels, wind turbines, hyrdogenerators, or anything else you choose to use. Note: The wire to make these connections is not supplied. You must use your own wire. Solar Panel Battery (1)

7 Step 6 : Connecting the generator positive terminal(s) to the relay DC Wind Turbine Diode Solar Panel Fuse Diode Connect the positive terminal(s) of all power generation source(s) to a diode. Then connect the diodes to the fuse holder. Make sure you remove the fuse from the fuse holder! Lastly, connect the fuse holder to Pin #30 on the relay using the female spade connector. Make sure to use appropriately sized wire to handle the power produced from your generator source(s). The wire for this connection is not supplied. For 3 phase AC wind turbines, follow the instructions in step #7.

8 Step 7 : Connecting the generator positive terminal(s) to the relay with 3 phase AC wind turbines (Proceed to Step 8 if you are not connecting a 3 phase AC wind turbine) 3 Phase AC Wind Turbine Fuse Solar Panel Diode ~ ~~ (3) (2) 3 Phase Bridge Rectifier (1) (1) Connect the three AC wires from the AC wind generator to your 3 phase bridge rectifier. (2) Wire the negative output from the 3 phase bridge rectifier in the same manner as in Step 5. (3) Wire the positive DC output from the 3 phase bridge rectifier as in Step 6. Note: the diode is NOT necessary and can be removed if you are not using a solar panel or some other DC power generating device. If you are using a solar panel or other DC power generating device, the diode MUST remain. Note: Use wire that can handle the power created by your power generation devices.

9 Step 8 : Installation of a float charge circuit (Only necessary if you choose to use the controller in noncycling mode) Connect to Pin #87a on the relay Connect to Pin #87 on the relay Diode Resistor NONCYCLE MODE ONLY! The diode can be nearly any diode. A 1N914 diode is a good choice. The resistor should be sized according to your battery size and type. The float charge circuit prevents the controller from switching on and off constantly while the batteries are charged. If you do not want to deal with this option, we suggest using the charge controller in CYCLING MODE. (See operating instructions for a explanation of both charging methods.)

10 Step 9 : Optional Fan Connection Charge Controller Same white wire from step 2. DC computer type fan Locate the blue and white wires coming out of the charge controller. Connect the blue and white wires to your DC computer type fan. WARNING: In order to avoid an explosion, a fan is necessary if you are charging your batteries in a nonventilated area. If you are charging your batteries in a ventilated area, a fan is not necessary.

11 Step 10 and 11 : Expanding your charge controller to 80 or 120 AMPS Your charge controller can be expanded to handle 80 or 120 AMPS. To increase your AMP capacity to 80 AMPS you will need to purchase an additional relay. To increase the capacity to 120 AMPS you will need to purchase two additional relays. IMPORTANT WARNING: Each relay can only handle S. For this reason, YOU CAN NOT EXCEED S INTO ANY GIVEN RELAY. Therefore, each individual power generating device you use can not exceed S. For example, if you upgrade your controller with two additional relays, you CAN use one wind generator that generates up to s, one solar panel that generates up to 40 AMPS, and one hydrogenerator that generates up to S. You CAN NOT use a wind generator that makes 120 AMPS even if you are using three relays. If one relay switches just a few seconds before the other two relays, 120 AMPS could flow through it and the relay WILL FAIL. Proceed to the next two slides for instructions on how to wire additional s.

12 Step 10 : Expanding your charge controller to 80 AMPS Diversion Load A Diversion Load B To battery () Diode Max. Solar Panel DC Wind Turbine To Pin #87a on 40 AMP A To battery () To Pin #87a on 40 AMP B To battery () Fuse To Pin #30 on A A Pin # 86 Pin # 86 Pin # 85 Pin # 85 To Pin #87 B To Pin #87 Battery Charge Controller Diode Fuse To battery () To Pin #30 on B Note: Proceed to the next slide to connect a third relay.

13 Step 11 : Expanding your charge controller to 120 AMPS If you are going to add a third relay, then it must be added in parallel with the fan output from the charge controller (blue and white wires coming out of the charge controller). Diversion Load C To Pin #87a on 40 AMP C To battery () C Charge Controller Pin # 86 Pin # 85 Connect to fan (If you choose to use one) DC Wind Turbine (or solar panel, etc.) Diode Fuse To battery () To Pin #30 on C To Pin #87 Battery Same white wire from steps 2 & 10.