Charge Controller
21Pages

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 1 of 21 Registration Number 2006/005438/07 VAT Registration Number 4870231406 Tel: +27 (0)41 401 2500 Website: www.kestrelwind.co.za Kestrel Charge Controller Type 0801 User Manual Revision 1.0 (04-08) For the following models of Type 0801 Charge Controller Type 0801-1000-012 (e300-002-012) 1000W 60A Type 0801-1000-024 (e300-002-024) 1000W 40A Type 0801-1000-048 (e300-002-048) 1000W 25A

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 2 of 21 CONTENTS PAGE 1 Safety Considerations 1.1 Mechanical Safety 3 1.2 Electrical Safety 3 1.3 Installation Hazards 3 1.4 Operational Safety 3 2 Charge Controller Overview 2.1 Charge Controller Description 4 2.2 Identification and Markings 5 2.3 Applications and Uses 5 3 Charge Controller Assembly 3.1 Components Supplied 6 3.2 Components not Supplied 6 3.3 Tools Required 6 3.4 Unpacking 6 4 Installation Instructions 4.1 Typical Installation Example 7 4.2 Mounting the Charge Controller 8 4.3 Electrical...

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 3 of 21 1 Saffetty Consiiderrattiions 1..1 Mechaniicall Saffetty 1..2 Ellecttrriicall Saffetty 1..3 IInsttallllattiion Hazarrds 1..4 Operrattiionall Saffetty Note: The Charge Controller Type 0801 must be installed with a separate divert resistor. Disclaimer Kestrel Wind Turbines makes every effort to give accurate information in this manual and is in no way liable for any error or omission. The user of this manual assumes full responsibility and risk. We appeal to your common sense to read and apply the...

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 4 of 21 2 Charrge Conttrrollllerr Overrviiew 2..1 Charrge Conttrrollllerr Descrriipttiion 2..2 IIdenttiiffiicattiion and Marrkiings 2..3 Applliicattiion and Uses 2 CHARGE CONTROLLER OVERVIEW 2.1 Charge Controller Description IMPORTANT: A suitable divert power resistor must be installed with this product Sustainable/renewable energy sources such as wind turbines and solar panels generate uncontrolled power that must be regulated to facilitate the correct and safe charging of storage batteries. The Kestrel...

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 5 of 21 2.2 Identification and Markings On the Charge Controller enclosure is a product rating plate and serial number, if the charge controller does not carry this stamp it does not carry a Kestrel warranty and may not be authentic. *NOTE: Product Rating label example (above) is for format only, specifications do not apply On the front cover of the charge controller are two circuit breakers which are labelled accordingly. Removing the front cover (shown below right) reveals connection labels. 2.3...

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 6 of 21 3 CHARGE CONTROLLER ASSEMBLY 3.1 Components Supplied The following components are supplied: Charge Controller assembly 3.2 Components Not Supplied The following components are necessary to complete an installation: Electrical crimp terminals Wall fixing screws 20mm cable glands 3.3 Tools Required The following hand tools are required for Charge Controller installation: Small size electrical screwdriver Medium size electrical screwdriver Wire strippers for electrical connections Electrical crimping...

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 7 of 21 4 INSTALLATION INSTRUCTIONS 4.1 Typical Installation Example A typical battery charging installation is shown below. The system comprises a Kestrel wind turbine, Charge Controller, Divert Resistor, battery and an inverter. The inverter is additional and converts the battery dc power into standard ac power such that common mains powered appliances can be supplied. NOTE: The load circuit breaker and inverter are additional equipment and not supplied with the charge controller. The diversion resistor...

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 8 of 21 4.2 Mounting the Controller The Kestrel Charge Controller Type 0801 is only suitable for indoor installation. The unit must be vertically mounted using the four external fixing holes provided. Use secure fastening with suitable wall plugs or bolts. Allow a minimum of 100mm (4”) space all around the unit for cooling. It is normal for the regulator to become quite hot at times as it dissipates unwanted energy. Do not place any objects on the top of the enclosure. The unit relies on the free passage...

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 9 of 21 4.3 Electrical Wiring Observe the Polarity at all times. Only connect +VE RED cables to +VE RED terminals and -VE BLACK cables to -VE BLACK terminals. Otherwise, equipment damage may result and any warranty will be invalidated. 9

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 10 of 21 PLEASE FOLLOW THE INSTRUCTIONS BELOW ! CONSULT SECTION 5 FOR WIRE SIZE RECOMMENDATIONS The Charge Controller is provided with three pairs of +VE and -VE clearly marked terminals for "TURBINE" and "BATTERY" and one pair of DIVERT RESISTOR terminals clearly marked R1A and R1B at the bottom of the regulator. The TURBINE BRAKE switch is designated “S1” and the BATTERY CIRCUIT BREAKER is designated “Q1”. The turbine brake switch stops the turbine by creating an electrical short on the turbine input....

Charge Controller Manual Document #: 0102M01 REV : 1.2 Approval: Date: March ’08 Page 11 of 21 4.4 Adjusting the Charging Voltage Always switch the turbine brake on (S1 ON) and the battery circuit breaker off (Q1 OFF) before adjusting the charging voltage jumper The Kestrel Charge Controller Type 0801 is suitable for all lead acid batteries whether vented, semi-sealed or sealed and the charging voltage may be adjusted. When the cover is removed, the jumper is visible in the middle of the control board. The charging voltage may be adjusted to the following table. There are five positions for...