C40 Locks Up

I have a PPSW5548/D with Trace C40 charge control and Xantrex TM500 battery status meter. The C40 freezes and locks up whenever the TM500 is connected. I originally installed this system with two C40's. Due to this problem I replaced the C40's several times at Trace tech's suggestion. After no improvement, I replaced the C40's with Outback MX60's which resolved the problem.

Now, two years later, I've removed one of the OB MX60's and replaced it with a C40 and, sure enough, the C40 locks up. I remove the TM500 Battery Monitor cable from the TM48 adapter in order to make the charge control work. With fall here, and winter on the way, I'd like to use the TM500.

By the way, the OB MX60 went to another system. I'd like to use the C40 and figure it should work with the TM500. Also, the Trace Techs were working on this problem (2 yrs ago) but never contacted me with a solution. Which is why I switched to Outback controllers. Anybody experience this problem, and more importantly, know of a fix or workaround?

The C40 freezes, light stops and remains off, and will not restart unless re-booted by removing both pv and battery power or by removing the TM500 communication cable from the TM48 on the shunt. The C40 passes through no amperage when in this "frozen" condition. This was a known error problem by the Trace techs when I last inquired in spring of 2003. I was told an engineer was assigned to the problem at the time. After several months of checking back and receiving no solution I replaced the C40's with the MX60's. At the time, I was told that Trace was maintaining a list of customers experiencing this condition. I was hoping that, by now, it has been resolved. I'd like to use these extra C40's that I have.

You point out two reasons why Xantrex seems to be stumped by this. One, there would appear to be little relation between the charge control and batt. meter. Two, the problem does not occur in every installation and seems (at least to me) to be related to the installation rather than the equipment. I've tried no less than six c40's and three tm500's with the same problem. I've checked equipment grounds, looked for sources of inductance or any other vodoo that may be affecting it.

Back in '03, when I had several conversations with Trace, one engineer admitted that this problem began surfacing after manufacturing of the c40 was sourced overseas (China).

I sent a recent email to Xantrex hoping to get a response on this problem with no reply so far. I'll let you know what I hear, if anything. In the mean time, I'd like to see a note in this forum from anybody who's seen this problem.

Edited by KOKeefe

well that explains it both my installs are 24 volt. how about calling the folks at trimetric i was told they made the tm500 and they seem to be the same as the trimetric maybe they have a answer?

Same problem after I put more than 8 amps charge into controller.
Observed all precautions (always disconnect batteries before PV, always connect PV before connecting to batts) and now:
When sun goes down, remote display/meter goes off.
I see nowhere that is supposed to happen.
Next morning I must - switch out batts, switch out PV, disconnect and reconnect meter line, reconnect pv and switch in batteries.

My recommendations? Only buy Xantrex c series used and for/as load controller - basically as a line conditioner (prevent overvolting of your electronics - some are very sensitive!) and go buy a real charge controller that is capable of performing as advertised.

Personally I feel that in view of the remark that these items have gone to hell since being farmed out to China I believe they may be the victim of the infamous 'chinese inch'. In tools, one chinese inch is equal to, less than or greater than a US inch depending on what day of the week it is, even or odd numbered years, and of course the local weather.