Wind generators factory
Unit 2, Building 2, Office 102, Pingxiang - Xingtai city,
Shijimingzhu, Guangchang Road, Hebei, China
 Phone: +86 13333 092 057 Email: iasos@iasos.eu
Traiding Company
Lianglima Pingxiang, Xingtai city,
Hebei, China 054500
Phone: +91 9823 1964 80 Email: coyote@iasos.eu
FF 5, First Floor, 77 Rosemin Arcade,
Aquem, Margao Goa, India 403601
Phone: +91 9823 1964 80 Email: jitendra@agarwalgroupco.com

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FIRST PAGE

Charger controllers C8501.
Hybrid controller for wind turbine and for PV.
Model:
C8501
Approximately Price:
MPPT CHARGER CONTROLLER FOR WIND GENERATOR AND FOR SOLAR
Maximum power :
1.000 watt
417 euro
A. Protection of the equipment.

The most modern electronic device, which provides protection not only batteries, but also wind turbine and solar. This ensures that the user will avoid unforeseen losses and maintenance costs.

B. Maximum performance.

Converts 98% of energy produced by the generator into usable electricity for the user.

C. Hybrid system.

There is not only to connect the wind turbine, but simultaneously and PV.

D. It can be connected to a computer.

Optionally offered the connectivity to a computer via ports: RS485, RS232, allowing the user to monitor all operating data and performance.

MPPT CHARGER CONTROLLER FOR WIND GENERATOR AND FOR SOLAR MPPT CHARGER CONTROLLER FOR WIND GENERATOR AND FOR SOLAR MPPT CHARGER CONTROLLER FOR WIND GENERATOR AND FOR SOLAR MPPT CHARGER CONTROLLER FOR WIND GENERATOR AND FOR SOLAR MPPT CHARGER CONTROLLER FOR WIND GENERATOR AND FOR SOLAR

BASIC PRINCIPLES OF DESIGN OF THE CONTROLLER - SPECIALIZED FEATURES.

1. The wind turbine, the batteries, and any external load has some internal resistance. To allow maximum performance and utilization of electricity, should the total input impedance is equal to the output impedance of the generator controller. In this principle is based on the design of this controller.

2. Incorporating technologies MCT and MPPT. When the wind speed is low and thus the rotational speed of the turbine of the wind turbine is small, then if the generator is burdened with high load, will further reduce the rotational speed of the turbine, with negative consequences in the overall system efficiency.
To avoid this problem, the controller is equipped with two special electronic devices. One monitors the maximum power current (max current tracking - MCT) and the other the instantaneous power (max power point tracking - MPPT). So having these two information, can automatically adjust the amount of load that can be borne by the generators, without disturbing the overall efficiency of the system.

3. Electronic Automatic calculation of the maximum capacity of the battery and automatic calculation of loading rate and maximum charging current. With equipment for three different charging modes, and even watching the batteries temperature, provide the ideal conditions of batteries and therefore their use in as many years.

4. Built-BUCK techology. Wind turbines have variable output voltage, depending on the wind strength. When the wind is strong and the tendency from the turbine is greater than the battery voltage, then the controller automatically reduces the voltage required to produce electricity to be fully exploited for charging the batteries.


Specifications hybrid controller for wind turbine and PV.
Model:
C8501.
Input voltage :
From 13 DCV to 70 DCV.
Maximum Power Point Voltage Tracking Scope:
12 DCV ~ 70 DCV.
Available energy inputs:
Two input way.
Can connect or two generators from wind turbine or one generator from wind turbine and one PV.
Rated working voltage:
12 DCV or 24 DCV auto switch.
Maximum charging current:
60 Α (30 A per each generator).
No load loss:
<45 mA
Charging mode:
Three different methods: Bulk - Absorption - Float.
Float charging voltage:
27.6V (Default). (Adjustable from the user).
Temperature compensation for float charging voltage:
-4mV/cell/C°
Absorption charging voltage:
28.8V (Default). (Adjustable from the user).
Temperature scope:
-20 ~ +70C°
Battery reverse connection function:
Yes.
Battery reverse discharging function:
Yes.
Wind turbine reverse connection function:
Yes.
Wind turbine input over voltage protection:
Yes.
Radiator overheat protection:
Yes.
Input over power deviated from maximum power point:
Yes.
Cooling way:
Thermostat active cooling.
Optional function:
(RS485 or RS232) remote controlling function.
Working temperature scope:
-10 ~ +50 C°
Working altitude:
3.000 m.
Working humidity scope:
0 ~ 90 %
Volume:
380mm*150mm*100mm
Weight:
5.8 Kg
Storage temperature scope:
-30 ~ +80 C°

User manual.
1. Safety precautions.
(1) Avoid any inflammable and explosive gases, corrosive gases, dust place when installing the controller.
(2) Avoid installing the controller directly under sunshine or rain.
(3) Please do not insert any object into the controller or spill liquid to the controller.
(4) Do not open or fix the controller by yourself.
(5) Do not touch the metal part on the controller when the system is working.
2. Introduction
2.1 Features

The controller C1160 main topology adopts in Buck conversion circuit, and uses MCU to adjust the wind turbine working point intelligently in order to make the wind turbine output its maximum power. When the circumstances change, the working point of wind turbine deviate from the maximum power point, MCU will adjust the wind turbine working point based on MPPT calculation to make the wind turbine back to the maximum power point again (refer to 2.3 about MPPT technology introduction).

Compared with PWM controller, C1160 controller can increase the output of wind turbine by 5%~30%. The output increasing proportion is affected by the factors such as the wind speed. At the LCD interface, this product adopts in big LCD screen lattice to show the parameters and states, using vivid icon to show individual parameters. The controller uses 4 buttons to realize interfaces shifting and parameter setting. The LCD screen is simple and concise, and the whole machine wall-mount installing (refer to chapter 4.1). Nylon terminal makes the wiring area bigger and wiring loss less.
2.2. Functions
2.2.1. Maximum power point tracking function.

Use Buck conversion circuit and MCU technology to track the maximum power point to realize the maximum output of wind turbine in different wind speed and this can gain more value for customers
2.2.2. Charging process controlling.
The starting charging voltage of battery is different, C1160 will use the different charging strategies to finalize the charging process. When starting charging voltage of battery is lower than 12.6V (for 12V battery), battery will go through three stages as Bulk, Absorption and Floating charging. When starting charging voltage of battery is higher than 12.6V (for 12V battery), battery will go through two stages as Bulk and Float charging.
Bulk charging: Controller charges the battery by its maximum output current. It is at maximum power point tracking state at this phrase.
Absorption charging: Controller begins to limit the charging current to make the battery voltage fixed at a settled absorption voltage(this voltage has temperature compensation) for 2 hours. This can increase t he charging saturation level of battery and prevent battery from leaking gas, and this can increase the longevity of battery.
Float charging: Battery is at saturation state, and the controller charges the battery at a small current to make the battery voltage fixed at the settled float charging voltage(this voltage has temperature compensation).
2.2.3. Charging voltage adjustable.
Users can adjust the float charging voltage within a certain range. And the default value is 13.8V (for 12V battery).
Users can adjust the absorption charging voltage within a certain scope. And the default value is 14.4V (for 12V battery).

2.2.4. Temperature compensation for charging voltage.
The controller C1160 will compensate the setting Float charging voltage and Absorption charging voltage by -4mV/Cell/°C based on the current battery temperature.
For 12V battery, the compensated voltage U=(t-25)*6*(-0.004)V
For 24V battery, the compensated voltage U=(t-25)*12*(-0.004)V
For 48V battery, the compensated voltage U=(t-25)*24*(-0.004)V

2.2.5. Temperature controlling fan.
The controller will detect the temperature of internal power module. When the module temperature exceeds a certain value, the controller will turn on the fan to take away the heat. It will turn off the fan when the temperature decreases to a certain value.

2.2.6. "Sleep" function.
When controller detects the voltage of the wind turbine is lower than the battery voltage, it will turn off part of the internal circuit to decrease the standby loss. At sleep state, controller will wake up every 4 mins to detect the wind turbine voltage and refresh the LCD data, so controller refreshes the data slowly at sleep state. If users need to check the current data, you can press any button to wake up the controller. If user haven't press any button within 1 min and the wind turbine voltage is still lower than battery voltage, the controller will be back to sleep state again.

2.2.7. Battery reversed connection protection.
Connecting the battery to the controller by reversed polarity (under the circumstances of not connecting the wind turbine) will not damage the controller. Controller can work normally after connecting right.

2.2.8. Wind turbine reversed connection protection.
Connecting the wind turbine with the controller by reserved connection will not damage the controller. Controller can work normally after connecting right.

2.2.9. Protection for battery reversed discharging.
The C1160 controller can prevent battery from discharging to wind turbine at low wind speed or any other event that the wind turbine not produces electricity.

2.2.10. Internal over-heating protection.
When controller detects the temperature of internal power module is higher than a certain value, it will stop charging to the battery, and it will restart charging the battery again when the temperature decreases to a certain value.

2.2.11. Over voltage protection for wind turbine input.
When the input voltage of wind turbine exceeds the maximum voltage permitted by the controller, it will enter into protection state automatically and stop charging the battery. When the input voltage recovers to the normal range, the controller will start charging the battery again.

2.2.12. Power limiting for the input of wind turbine.
When the power of wind turbine is too big, the C1160 controller will deviate from the maximum power point to limit the output current to prevent the controller being damaged.

2.3. MPPT technology introduction.
The electricity from wind turbine are nonlinear power, and the output power is mainly affected by wind speed and the load impedance. When the wind speed and is fixed, the output power of wind turbine is only affected by load impedance. Different load impedance will make the wind turbine work at different point and put out the different power. The following figure will mark the four working points A, B, C, D, and the working point features as follows:

Working point D: Output voltage is 22.3V, output power is 0W. This point is the open circuit point of wind turbine.
Working point C: Output voltage is 0V, output power is 0W. This point is the short circuit working point of wind turbine.
Working point A: Output voltage is 13V, output power is 74W.This working point is the state when using normal controller, and the wind turbine voltage is clamped to 13V by battery.
Working point B: Output voltage 17.6V, output power 92W. This point is the state when using MPPT controller. Because of using power conversion technology, the wind turbine voltage is not clamped by battery and still works at maximum power point.
Compare working point A & B, it is easy to find using MPPT controller can increase the using efficiency of wind turbine. Compared to normal controller, eMPPT controller can generate more power.

MPPT CHARGER CONTROLLER FOR WIND GENERATOR AND FOR SOLAR
MPPT CHARGER CONTROLLER FOR WIND GENERATOR AND FOR SOLAR
MPPT means maximum power point tracking. It makes the wind turbine work at maximum point (ext Point B) by using power conversion technology. The C1160 with MPPT technology is the new charge controller researched and developed by our company, and it uses the MCU to track the maximum power point of wind turbine intelligently to generate more power from the wind turbine.

3. System Design.
The controller can accept two independent input sources (with two input channels) that may be even solar panels.

3.1. System voltage.
The common system voltage of solar DC system has 3 types: 12V, 24V and 48V. The higher the system voltage, the more power the system can handle. In reality application, users should consider the load power, and the voltage scope permitted by load, and then confirms which system voltage you should use. The power range for each system voltage is as follows:
With nominal voltage 12 DCV the controller can accept power 800 watt.
With nominal voltage 24 DCV the controller can accept power 2.000 watt.
With nominal voltage 48 DCV the controller can accept power 6.000 watt.

3.2. Wiring.
The maximum input current per channel is 30A. To ensure the cable temperature does not exceed the safety range, the copper cable's area must be bigger from 6 mm² .
The maximum output current is 60A. To ensure the cable temperature does not exceed the safety range, the copper cable's area must be bigger from 12 mm².
In reality application, users can choose the appropriate cables according to the system voltage, permitted cable temperature, cable voltage drop and also cable material.
We suggest customer to control the maximum battery voltage loss under 1.5%, and control the maximum voltage loss of wind turbine under 2.5%.
The TABLE 1 shows the ideal profiles for the wiring to and from the controller.

3.3 Over current protection.
The electrical equipment used in power circuit must be equipped with over current and short-circuit protection devices, and there is no exception for C1160 controller. The C1160 controller adopts in the design of sharing positive pole inside. We suggest users to install over-current breaker or fuse on the negative loop of wind turbine input, and also the negative loop of battery output. The capacity of over-current breaker or fuse is 1.25 times of the rated current.

3.4. Lightning protection.
It is the same as other electrical devices that the C1160 controller will be damaged by lightning. The controller has limited surge absorption capacity. We strongly suggest users to install lightning surge absorption devices to increase the reliability of the system.

3.5. Grounding.
The C1160 controller has protection grounding terminal. Use 4 mm² yellow and green lines to connect the grounding terminal of the controller to the ground bus of the system. This can decrease the electromagnetic interface in a certain value.

3.7. System expansion.
If users want to deploy bigger system, you can expand the system by paralleling several sets of controller. More controllers can share one battery group, but one controller must be connected with one or two independent generator.

4. Installation.
4.1. Product dimension.
MPPT CHARGER CONTROLLER FOR WIND GENERATOR AND FOR SOLAR

Mounting hole pitch: 358mm*218mm
Mounting hole diameter: Φ6mm
Height*Width*Thickness: 386mm*283mm*100mm
Connecting Terminals: Wind turbine input M6, battery output M8

4.2. Wiring device.
Choose the appropriate cross section cables, as mentioned in the previous chapter.
Use terminals for cable 6 mm² or 10 mm² hole 6 mm. Use screws to fasten Φ6.
Study and apply the connection mode as shown in each individual wind turbine model.

4.3. Installing process.
Note: Please turn off the breakers of battery and enable the handbrake of wind turbine before installing the controller. If you install together solar panels, do not touch the positive and negative pole of solar panels or battery at the same time when installing, otherwise you have the risk of electrical shock..
A. Check whether the battery voltage and wind turbine voltage is within the requested range.
B. Open the over-current breaker or fuse of the battery and wind turbine.
C. Use crimping to press the Copper cable lugs to the cables. Make sure laminated is match able with the cables, and the Copper cable lugs is match able with the cables, otherwise it will have the risk of over hot.
D. Connect the battery with the battery terminal on controller by cables and fasten the screws. Connect the wind turbine with the wind turbine or solar terminal on controller by cables and fasten the screws.
E. Connect the grounding terminal on the controller to the ground bus of the system.
F. Insert the incidental temperature sensor into the pole on the button of the controller.
G. If you have choose to install RS232 remote monitoring function, you can connect the computer or remote monitor with the computer communication port on the controller.
H. After getting through the over-current breaker or fuse of the battery, please check the LCD screen, at this time the LCD should show the battery voltage info. LCD showing normally means the connecting is right and you can go to the next step. Otherwise refer to chapter 6 for disposal.
I. After getting though the over-current breaker or fuse of the wind turbine, check LCD screen, and controller will show the current voltage of the wind turbine. If the wind turbine voltage is higher than battery voltage, controller will start maximum power point tracking and the wind turbine voltage begins to drop. If the controller is at sleep state, press any button to wake up the controller.
Note: Suggest you install the controller on the vertical surface and make sure there is space about 10cm around the controller to make better cooling.
Suggest you save 20cm on the bottom of the controller to make the connection of cables convenient.

5. Operation
5.1 Button function.

The TABLE 2 shows in detail the functions of the buttons.

5.2. LCD interface instruction.
The showing interfaces consist of 5 interfaces. Each interface has 4 lines.
The first line is the state indication line, and it indicates the working condition of the whole system or the breakdown information.
The icon of the upper right corner of each interface is indication of the current interface.
The first number means the current interface, and the second one means the whole interface.
Please visit the TABLE 3 to check the functions of each interface (take 24V system as an example).

Description of the display messages.
MPPT CHARGER CONTROLLER FOR WIND GENERATOR AND FOR SOLAR

"1" It means there are 7 pages, and now it is the first interface.
"2" It means controller has internal breakdown.
"3" It means the controller detects breakdown, and it will prompt to the users. And please refer the disposal to chapter 6.
"4" It means the controller is in sleep state if this icon appears.
"5" Means the current charging stages:
MPPT means it is in Bulk charging stage.
ABSB means it is in Absorption charging stage.
FLOT means it is in Float charging stage.
CLTD means the wind turbine power is too big, and the controller starts to limit the current.
"6" It means the current wind turbine or solar panels voltage.
"7" It means the current battery array is 24V and the battery voltage is 26.1V.
"8" It means the total charging current for battery is 27.1A.
"9" It means the accumulative charging AH is 13120AH.
"10" It means the environmental temperature of controller is 25°C.
"11" It means the charging power from controller to battery is 707W.

5.3. Battery parameters viewing.
Battery parameters will be showed at the first page of the main page. It includes the parameters as battery voltage, charging current, charging state, environmental temperature and accumulative charging AH.

5.4. View and clearing of generating data.
Generating data is in the second page It includes the accumulative generating AH of the controller and the generating AH for yesterday. Press OK button for 5 seconds and it enters into the confirming page of clearing the accumulative generating AH. Press this OK button for 5 seconds again, you will clear this data. Press ESC for short can cancel the setting. No operation in 20s, it will exit this page automatically.

5.5. View and setting for Absorption charging voltage.
Absorption charging voltage data is in the third page. Press OK for 5 seconds, and it enters into parameter setting state. Wait until the pending setting parameter flicking, press +, - shortly to adjust the parameter, and the adjusting step is 0.1V. Press OK for 5 seconds can save the revised the parameter. Press ESC shortly to exit the page without saving the revised data. Press OK and it can switch to another setting parameter. No operation without 20s, the controller will exit the adjusting state.

5.6. View and setting for float charging voltage.
Float charging voltage data is in the third page. Press OK for 5 seconds, and it enters into parameter setting state. Wait until the pending setting parameter flicking, press+, - shortly to adjust the parameter, and the adjusting step is 0.1V. Press OK for 5 seconds can save the revised the parameter. Press ESC shortly to exit the page without saving the revised data. Press OK and it can switch to another setting parameter. No operation without 20s, the controller will exit the adjusting state.

5.7. View and setting for Language.
Language selection page is the forth page. Press OK for 5 seconds, and it enters into language selection page. Press +, - to choose your target language. Press OK for 5 seconds to save the revised data. Press ESC shortly to exit the page without saving the revised data. No operation in 20s, the controller will exit the page.

5.8. View and setting Controller communication number.
The setting of the controller communications number is at the forth page. At this page, press OK for 5 seconds to enter into language setting state; press OK shortly to switch into controller communication number setting state; use +, - to adjust the communication number; press OK for 5 seconds and the modified data can be saved. Press ESC shortly to exit the page without saving the modified data. The controller will exit the parameter adjusting state automatically if no operation on the controller in 20s.

5.9. Parameters to the factory default value.
Use +, - to switch the page to the fifth , Press OK for 5 seconds to enter into the page to recover the default. Press OK again for 5 seconds to confirm it. Press ESC shortly to exit the page. No operation within 20s, the controller will exit the page automatically.

6. Troubleshooting
6.1. Error code meaning and disposal.
The interpretation of error codes, shown in TABLE 4.
6.2. Common breakdown phenomena and disposal.
Visit TABLE 5 for relevant information.