Enclosed in a weather tight, hinged door, industrial duty instrument box.
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.
Use this controller to regulate and prevent battery overcharge in:
Also works as a Disconnect Controller
This controller works by either diverting the charge source to a diversion or "Dummy" load, or if you prefer, you can simply disconnect the charge source from the battery -- Works either way!.
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 - 80 amps with the two 40 amp relays installed.
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.)
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 minimum 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.)
Settings are user changeable!! By simply turning a simple potentiometer with a small screwdriver, you can quickly adjust the trip point.
High amp rating -- 80 Amps! -- This is a bigger controller than the popular X-brand models that cost twice as much.
80 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, weather tight industrial duty instrument box. - Ready to mount. -- No plastic, no junk, simple and rugged.
You will love the enclosure. If you were to purchase this box separately, you could expect to pay more for the box then the entire controller!
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. We'll be happy to send you a diagram -- this is a very simple change.
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 an enclosure that's actually ready to use?
Is the enclosure weather tight?
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?
When you compare this controller to the others, you will see why we built it and why we know you'll love it.
Here are some of the most common ways to wire the controller. -- Click the image to enlarge
Note: The controller shown in the diagrams below is our C160, the wiring for the C80 and C160 is the same.
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 on Ebay in the last couple of weeks.
PERFECT ! DIVERSION CONTROLLER IS PERFECT ! WISH I COULD GIVE HIGHER RATING !
A very good packaged product.The instructions are an easy read.
As advertised good e-bayer
Item as described, 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.
Our own line of wind turbines built right here
in our CNC shop.
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