TrakMax 40 User Manual Revision 1.
TrakMax 40 User Manual Revision 1.0 Table of Contents 1 2 3 4 5 6 7 Introduction .................................................................................................................................................................. 3 1.1 Limited Warranty ............................................................................................................................................... 3 1.2 Restrictions ..........................................................................
TrakMax 40 User Manual Revision 1.0 1 INTRODUCTION Windy Nation Inc. (“Windy Nation”) is not assembling the wind unit, installing the solar system, or any other product offered by Windy Nation. Windy Nation, and its directors, officers, and employees disclaim, and by purchasing a Windy Nation wind or solar powered product you accept all liability and responsibility for damage to property, injury, or death arising out of or related to the use or misuse of any product offered by Windy Nation. 1.
TrakMax 40 User Manual Revision 1.0 defective Product to repair or replace such Product. If a warranty claim is invalid for any reason, the Customer will be charged at Windy Nation’s then-current rates for services performed and will be charged for all necessary repairs and expense incurred by Windy Nation. If Windy Nation determines that a warranty claim is valid, it will ship the repaired or replaced Product to Customer at Windy Nation’s cost. 1.
TrakMax 40 User Manual Revision 1.0 2 PRODUCT OVERVIEW The TrakMax solar charge controller is a 40 amp 12/24 Volt Maximum Power Point Tracking (MPPT) photovoltaic (PV) battery charge controller. Through the use of MPPT technology, TrakMax can increase charge current up to 30% or more compared to conventional solar charge controllers. TrakMax’s sophisticated three stage charge control system can be configured to optimize charge parameters to precise battery requirements.
TrakMax 40 User Manual Revision 1.0 Overload Protection (DC load) Bulk Charge (adjustable) Floating Charge (adjustable) Equalization Charge Overcharge Disconnection Overcharge Recovery Over-discharge Disconnection Over-discharge Reconnection Temperature Compensation Lead Acid Battery Settings NiCad Battery Settings Load Control Mode 2.0*Inom>5s 1.5*Inom >20s 1.25*Inom temperature controlled 14.6V(default) 29.2V(default) 13.4V(default) 26.8V(default) 14.0V(default) 28.0V(default) 14.8V 29.6V 13.6V 27.
TrakMax 40 User Manual Revision 1.0 3 INSTALLATION Insure all terminating connections are clean and tight to prevent arcing and overheating. Do not connect to a PV array capable of producing greater than 40 amps of short circuit current @ 25°C. Do not connect to a PV array with an open circuit voltage (VOC) greater than 55 VDC. For 12 volt battery charging, the open circuit voltage of the PV array must be between 12-30VDC.
TrakMax 40 User Manual Revision 1.0 3.3 GROUNDING The TrakMax is designed to work with grounded electrical systems. In the controller, ground is not connected to the input terminal and output terminals. Use a copper wire to connect the grounding terminal on the TrakMax enclosure to earth ground. The grounding terminal is located on the lower right corner of the enclosure. Do not connect the system negative conductor to this terminal.
TrakMax 40 User Manual Revision 1.0 3) Terminal connectors for DC wiring are located on the lower edge of the circuit board. Once the wires have been installed, tighten the terminals with the screw located on the top of the terminals to 1.2Nm (10.6lb-in). Be careful not to over tighten. Tighten Terminals Here Insert Wire/Cable Here a) Load: Maximum 15A DC Load • Connect a cable from the TrakMax terminal marked load negative (–) to the negative terminal of your DC load and tighten the screw.
TrakMax 40 User Manual Revision 1.0 3.5 OVERCURRENT PROTECTION Circuit breakers or fuses must be installed in both the battery and solar circuits. The protection device ratings and installation methods must conform to NEC requirements. The battery circuit fuses or circuit breaker must be rated to 125% of the maximum current or more. The minimum fuse/breaker rating allowed for use with each TrakMax is 1.25 x 40 Amps = 50 Amps.
TrakMax 40 User Manual Revision 1.0 3.8 COMMUNICATION PORT Network connections allow the TrakMax to communicate with other controllers or computers. 3.8.1 Remote: RJ11 Use standard 4-wire or 6-wire RJ-11 telephone cables (straight-through, not a Null Modem / cross-over). If possible, pull the telephone cable through conduit before crimping on the RJ-11 connectors. If using preassembled cables, take care not to damage the plugs when the cables are pulled through conduit.
TrakMax 40 User Manual Revision 1.0 Battery Type 12 Volt Units 24 Volt Units Lead Acid 0.03 volts (30mv) per degree Celsius 0.06 volts (60mv) per degree Celsius NiCad 0.02 volts (20mv) per degree Celsius 0.04 volts (40mv) per degree Celsius 3.9.2 Wiring the Battery Temperature Sensor (BTS) 1) Plug the provided RJ11 cable into the RJ11 socket labeled “BTS” located on the side of the TrakMax as shown below. 2) Secure the BTS on the side of the battery below the electrolyte level as shown below.
TrakMax 40 User Manual Revision 1.0 power, than a hot PV array. When PV voltage is sufficiently high for MPPT to operate, a constant power output is delivered to the battery. Since output power is constant while MPPT is operating, a decrease in battery voltage produces corresponding increase in charge current. This means that the greatest current increase occurs with a combination of cool ambient temperature and low battery voltage.
TrakMax 40 User Manual Revision 1.0 4.2.2 Three Stage Charge The TrakMax is configured for a three stage charging process, Bulk, Absorption and Float. The three stage charge process provides a somewhat higher charge voltage to charge the battery quickly and safely. Once the battery is fully charged a somewhat lower voltage is applied to maintain the battery in a fully charged state without excessive water loss.
TrakMax 40 User Manual Revision 1.0 5) Reset the BATTERY TYPE SELECTOR potentiometer to the appropriate setting for the system batteries when the Equalize charge has completed 4.3 DC LOAD CONTROL The TrakMax can operate as a PV charge controller and can regulate up to 40 Amps of continuous photovoltaic (PV) array current at 12 / 24-volts DC for charging batteries.
TrakMax 40 User Manual Revision 1.0 • Equalize: During an equalization cycle, the charging voltage will be held constant at the specified voltage setting. Switch Position Battery Type 12 Volt 24 Volt Charge Function Float Bulk Float Bulk Stage Equalize Stage Equalize (Volts) (Volts) (Volts) (Volts) Equalize charge rate Time Battery Capacity 6 hrs. (Min) / 12 hrs. (Max). Equalize Rate: Battery Capacity (A/hrs) / 40. Battery Charger Rate 6 hrs. (Min) / 12 hrs. (Max).
TrakMax 40 User Manual Revision 1.0 A solid green LED indicates the charging source is functioning properly. A flashing green LED indicates an error condition exists. The multi-color LED indicates the particular operating mode and the battery capacity level. 5.1 CHARGE CONTROL Battery Capacity: LVD >LVR LED Indication: Red Orange Green Figure 5.1: Battery Capacity LED indicators 5.
TrakMax 40 User Manual Revision 1.0 5.2.1 Low Voltage Disconnect (LVD) When a DC load is connected, if voltage remains below the Low Voltage Disconnect setting, the controller will disconnect after a 6minute delay period. The controller will wait until the voltage rises above the Low Voltage Reconnect setting. 5.2.2 Over Voltage of Load If the controller detects an over voltage of load, it will disconnect the load 5.2.
TrakMax 40 User Manual Revision 1.0 automatically when the unit first receives power. PV open circuit voltage must be 12-30VDC for 12VDC battery charging, and 30-55VDC for 24VDC battery charging. Charge current or PV current is • Check battery voltage, current is reduced if battery voltage is at set points. lower than expected • Check atmospheric haze, dirty PV’s, or sun low on horizon, etc.
TrakMax 40 User Manual Revision 1.0 batteries and are rated at 80 to 100 amp-hours at 12volts. Many larger systems use L16 batteries, which are usually rated at 350amp-hours at 6-volts each. They are 17 inches high and weigh about 130pounds. 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. 7.1.4 Sealed Batteries Another type of battery construction is the sealed gel cell.
