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Below is a description
of the complete charge controller - this kit does not contain
the enclosure and it has one 40 amp relay only - not
4 relays.
Please see
our other listings if you would like to purchase the completed controller.
This diversion controller is the
result of our many attempts to use the controllers
currently on the market (offered by some of the largest names in
the business), to work in conjunction with our wind turbines. None
of the other diversion controllers on the market did what we needed
a diversion controller to do. So we designed our own -- and added
all of the features that are truly needed in a diversion controller.
Some of the key features of this controller
are:
Microprocessor controlled -- This is very
important for both stability and functionality.
User changeable settings -- Several controllers
on the market set the dump level, and that's that!
High amp rating - 160 amps with the 4
relays installed -- You may add more if you actually need
more amps.
Battery status LED - Several controllers
do not tell you what's going on - This one does!
Push to test. Ever wonder if your controller
& load are working OK?
Steel enclosure, with two conduit
openings.
Large enough terminal blocks that you
can actually terminate large wire (See notes below.)
Super large heat sink -- Pulling in multiple
relays takes energy - which generates heat. This one handles it!
RJ-11 Serial interface. --This allows
connection to a computer for both programming and remote status
(See notes below.)
Can divert the source from the batteries
to the load, or dump both the batteries along with the source.
Some specifics about the points made above.
The microprocessor is the heart of
the controller. It is given the battery voltage and
the user changeable trip points. This information is analyzed
and acted upon.
The Battery level is checked, and based
on that info, the Green LED flashes
or is illuminated as follows
(One) Flash indicates the battery
is less than 12 volts (12 volt system - Double for 24 etc)
(Two) Flashes indicates the battery
is 12 to 12.5V
(Three) Flashes indicates the battery
is 12.6 to 13v
(Four) Flashes indicate the battery
is 13.1 to 13.5V
( Five) Flashes indicates the battery
is above 13.5V but less than 13.9V (Settings are adjustable)
Steady green means the battery
is full.
The red LED is illuminated
when the battery is being dumped at 14.5v (or the charge
source diverted.)
The dump remains active for
a min. of 5 seconds, at which time it is checked by the
microprocessor. If battery voltage drops below the "Dump
Cancel " level, the dump is disabled, otherwise the dump is
continued and rechecked every 5 seconds.
When you click the "TEST" push-button
- the 5 second cycle is started (one time, unless the batteries
are within the "Dump start" and "Dump Cancel" zone.)
For those who like to get into
the heart of the circuits -- We will include both the circuit
schematic and the actual program that runs the microprocessor.
The microprocessor is a Picaxe-08M, this is a great little
chip that allows almost anyone with a little basic programming
ability to learn and use quickly. If you wish to work with
the circuit at this level, you need to have the PICAXE software.
This software is available from PICAXE (possibly free). You will
also need a RJ-11 to Serial cable. Please Note: For the average
user, you will not need (or want) this additional information
nor these optional items.
Settings are user changeable!!
By simply turning a simple potentiometer with a small
screwdriver, you can quickly adjust the trip point.
If you are a DIY type of person,
you can modify the program directly -- it will do whatever you
program into it!
High amp rating -- 160 Amps as configured!
-- This is a big controller.
There
is nothing stopping you from adding more relays for nearly an
unlimited amount of load capability.
The
following precautions must be taken into account if you wish to
add more relays.
The
internal regulator can handle 12 relays (40 amp automotive type)
in a 12 volt system and 4 relays in a 24 volt system. The reason
for the smaller number of relays in a 24v system is the
regulator must convert the high battery voltage down to 15 volts
for the relay coils, this generates heat. So if you want
to add more relays than 4 (or 12), then simply use one
of the relays to switch on the coils of the other relays. This
will allow you to pull in as as many relays as your wire can
handle.
About
wire size -- 160 amps is a lot of current! -- The terminal blocks
inside the case will handle #8 wire and are better used
for switching loads of 60 amps or less. If your system
will likely run at the high end, then a better connection is
to simply remove the two relay contact wires from the internal
terminal blocks and terminate them to your larger wire directly
via a wire nut, or compression lug etc.
The enclosure is heavy gauge, solid
steel - Ready to mount. -- No plastic, no junk, simple and rugged.
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.
The source of power (wind turbine, solar
panels etc.) -- should remain connected to the batteries while
the dump is active.
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
level voltage 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 it's design realm --
always a good thing.
The
internal relays are configured to dump the batteries along with
the source, but if you desire to disconnect the source from the
batteries and send it to the load directly, simply utilize the
N/C contacts of the relays as well. See the wiring diagrams
below for further information.
How to compare
this controller to others on ebay (or anywhere!)
Do they have battery status indication?
Do they have a dump active indication?
Are the dump levels user
changeable?
Are they microprocessor controlled?
Do they come with a enclosure that's
actually ready to use?
Can they truly pull in multiple
relays without burning up or do they need fans?
Do they handle the amperage you need?
Do they have a dump test capability?
Can they be hooked up to your PC?
Do they include the program and circuit
schematics?
When you compare
this controller to the others, you will see why we built it and
why we know you'll love it.
THIS AUCTION
IS FOR THE KIT ONLY
Please note: The above text talks
about the fully completed charge controller. THIS AUCTION
IS FOR THE CIRCUIT BOARD ONLY AND INCLUDES THE FOLLOWING ITEMS ---
ONLY.
Circuit Board with all components
that belong on the circuit board including heat sink -- loose
(in bags), not soldered into place.
1 green LED
1 red LED
1 pushbutton
1 12v - 40 amp relay
5 connectors for the relay
3 wire harnesses for the LEDs
and pushbutton
Schematic
Instructions suitable for a knowledgeable
person.
**** NO ENCLOSURE IS PROVIDED ****
Please
note -- this kit is for those wanting
to build the circuit themselves and save a few dollars. You should
only attempt to do this if you have some electronics experience
and are comfortable soldering tiny components. If you would
like the completed circuit board or fully completed controller,
please see our other listings.
Here are some of the
most common ways to wire the controller. -- Click the image
to enlarge
Since many of us often don't
want to take a chance on something from a smaller business,
and tend to think that big named products are always better.
I thought it might help to pass on some of the feedback from
those who have purchased this controller in the last couple
of weeks.
Full
Controllers:
A
very good packaged product.The instructions are an easy
read.
As
advertised good e-bayer
Item
as discribed ,fast shipping
Great
Seller! FAST Shipping! A+++
Great
product. Got everything working great! Thanks!
ITEM ARRIVED VERY QUICKLY, VERY WELL PACKAGED, RECOMMENDED
SELLER
We burnt out two (x-brands)
40 amp models with a 20 amp wind generator, so we knew it was
time to solve the problem and create something that could actually
do the job. That's what this controller is all about; simple
compared to the big brand names, but perfectly in tune with
it's mission, save the batteries and keep the turbine spinning.
More
to come:
Put us on your watch list, we are currently working on a series
of new products specifically for the solar/wind market, including
a microprocessor controlled Delta/Wye (Star/Delta) auto switch
with electronic over-speed protection wind turbine controller.
Big things are happening
from a lot of little companies, and if you notice the truly
innovate products are being released from the new kids on the
block.
Perfect for experimenter, DIYer.
All of the components and PCB board, just solder it all
together and you have a controller that is very expandable,
and very economical. No enclosure is included
Thanks For Looking!
By popular request, here is the beginning
of a new series of documents that shows just how all of these components tie
together.
Please note: This kit will work when
properly assembled via the instructions in the
manual. This is a great controller, at a great price, but; if
you put components in backwards, put them in the wrong place, or are not able to
follow the directions, your kit may not work when you finish.
We can not offer trouble shooting services for this
kit, so please do not purchase this kit unless you feel you would be able
to trouble shoot the circuit should you run into problems.
We recommend you download the manual before purchasing. Please visit our store
for this same board fully assembled, tested and
calibrated.
*The estimated delivery time is based on the seller's handling time, the shipping service selected, and when the seller receives cleared payment. Sellers are not responsible for shipping service transit times. Transit times may vary, particularly during peak periods.
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