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Xantrex XPLORE 120/12, Owner'S Manual, Page: 33 / 68

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Xantrex XPLORE 120/12 Owner'S Manual Download Page 33

Installing the XPLORE 120/12 Battery Charger

975-1038-01-01

21

Installing the XPLORE 120/12
Battery Charger

Be sure to read the safety guidelines and pay attention to all
cautions and warnings throughout the installation procedure. The
installer is responsible for ensuring compliance with the
installation codes for your particular application. See CAUTION
statement under

Preparing For Installation

.

DANGER

ELECTRICAL SHOCK HAZARD

Disconnect all sources of AC and DC power before proceeding.

Failure to follow these instructions will result in death or serious
injury.

Summary of Contents for XPLORE 120/12

Page 1: ...XPLORE 120 12 Battery Charger Owner s Guide Model XPLORE 120 12 Battery Charger 819 0120 12...

Page 2: ...ENTIRELY AT THE USER S RISK AND C REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION THE ACCURACY CANNOT...

Page 3: ...and be sure to keep your proof of purchase Serial Number ____________________________ Product Number ____________________________ Purchased From ____________________________ Purchase Date ___________...

Page 4: ...cing the hazards involved in performing electrical work l Selecting and using Personal Protective Equipment PPE Related Information You can find more information about Xantrex products and services at...

Page 5: ...been dropped or otherwise damaged in any way take it to a qualified service person 7 Do not disassemble charger take it to a qualified service person when service or repair is required Incorrect reas...

Page 6: ...hium Ion batteries only The charging terminals are not intended to supply power to an extra low voltage electrical system other than in starter motor or power storage applications Do not use battery c...

Page 7: ...cords to reduce risk of damage by hood door or moving engine part b Stay clear of fan blades belts pulleys and other parts that can cause injury to persons c Check polarity of battery posts POSITIVE...

Page 8: ...ent grounding conductor should be run with circuit conductors and connected to equipment grounding terminal or lead on battery charger Connections to battery charger should comply with all local codes...

Page 9: ...the FCC CAN ICES 003 Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates...

Page 10: ...ccording to local regional or national environmental regulations Many of the electrical components used in the XPLORE 120 12 Battery Charger are made of recyclable material like steel copper aluminum...

Page 11: ...17 Configuring Charge Current for Battery Size 20 Installing the XPLORE 120 12 Battery Charger 21 Installation Sequence 22 Battery Operation 31 Input Voltage Operating and Derating 31 Dual Chemistry...

Page 12: ...bleshooting 45 Maintaining the Charger 46 Troubleshooting 47 Specifications 51 Physical Specifications 52 Environmental Specifications 52 AC Input Specifications 53 DC Output Specifications 53 Protect...

Page 13: ...y bank charging features suitable for Recreational or Commercial Marine installations Please read this section to familiarize yourself with the main performance and protection features of the XPLORE C...

Page 14: ...board battery type selection n programmable charge settings for a Custom battery type n universal input AC line voltage ranging from 80 270 VAC 50 60Hz n automatic charge resumption after AC power int...

Page 15: ...ounting orientations The following accessories are available for the XPLORE Charger a n The included Xantrex BLE Module PN 808 0889 provides the following features o connect to the XPLORE Charger s ex...

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Page 17: ...ection identifies the default settings and the hardware features of the XPLORE 120 12 Battery Charger This section includes Front Panel 6 Terminals and Ports 7 Onboard Status LED Panel 8 Accessories 9...

Page 18: ...stall the product B Onboard status LED panel see Onboard Status LED Panel on page 8 for more information for monitoring charging status for the three banks C Wiring compartment cover protects the DC a...

Page 19: ...al output Item Description G Battery positive for BAT2 group 1 120A total output H Battery positive for BAT1 group 1 120A total output I Battery negative common for all six banks J Dry contact port fo...

Page 20: ...tatus LEDs n Solid battery is fully charged float stage n Flashing battery is being charged bulk and absorption stages A 0 5 Hz flashing sequence indicates 0 to 25 SOC 1 Hz 25 to 50 SOC 1 5 Hz 50 to 7...

Page 21: ...1038 01 01 9 Accessories This section lists all available accessories for the XPLORE 120 12 Battery Charger To order contact Xantrex or your authorized dealer Battery Temp Sensor BTS with 25 ft cable...

Page 22: ...This page is intentionally left blank 2...

Page 23: ...tallation instructions regarding your XPLORE Charger This section includes Preparing For Installation 12 Tools and Materials 14 Location 14 Wiring Requirements 17 Configuring Charge Current for Batter...

Page 24: ...oat and Yacht Council ABYC standards and US Coast Guard Regulations 33CFR183 Sub Part I for Marine installations in the USA Failure to follow these instructions can result in equipment damage NOTE The...

Page 25: ...und bus B AC terminals G L N protected by fuses H Battery cable neg C Battery positive terminals for BAT3 through BAT6 Group 2 I Battery cable pos D Battery positive terminals from left to right for B...

Page 26: ...se n a properly rated circuit breaker or a DC fused disconnect for each battery n a 2 way cable gland electrical junction box n four pieces mounting screws 10 corrosion resistant Length dependent on m...

Page 27: ...ets standards to prevent dripping water from entering the enclosure and causing shock hazard and damage to equipment The other possible mounting orientations will not prevent the entry of dripping wat...

Page 28: ...Orientations deck versus wall IP rated n Vertical Wall Mount Wiring panel facing down this meets IP32 requirements and is drip proof n Deck Mount this orientation is not recommended for IP rated orien...

Page 29: ...with all applicable codes and standards Ensure that wires and fuses or breaker disconnects are correctly sized Maximum continuous DC current available from the charger may be an additional 6 10 above...

Page 30: ...in case of any overcurrent or short circuit fault AWG Max Fuse Breaker 3 150 A 4 150 A 6 60 A Table 2 Fuse Sizes versus Wire Sizes AC Wiring DANGER FIRE HAZARD Use only on circuits provided with 20A...

Page 31: ...al Code NEC allows solid wire in multi conductor cable however stranded wire is also acceptable which will withstand vibration better Conductors and flexible cords shall be stranded copper for the mar...

Page 32: ...tween 5 to 120A see Changing the Charge Current on page 1 Remember to always adjust the charger current based on the battery size to ensure a proper charging of the battery For example a 20 amp charge...

Page 33: ...warnings throughout the installation procedure The installer is responsible for ensuring compliance with the installation codes for your particular application See CAUTION statement under Preparing F...

Page 34: ...e of condensation Other possible mounting orientations will not prevent the entry of dripping water and are not suitable for use in moist environments To mount the XPLORE Charger 1 Select a mounting s...

Page 35: ...he procedure for installing the DC wiring applies to a single battery as well as multiple batteries or battery banks WARNING ACCIDENTAL SHORT OR SPARK HAZARD Leave the DC disconnects or breakers in th...

Page 36: ...the positive red and the negative black NOTE You may find it helpful to label each cable associating it with the battery bank it is connected to For example NEG BAT1 BAT2 and so on 3 Install a DC cir...

Page 37: ...re the negative terminal of the XPLORE Charger will be connected to the battery negative terminal or DC negative bus Connect the negative cable to the negative DC terminal on the charger 6 Connect the...

Page 38: ...t the free end of the negative cable to the correct negative terminal of the battery using sufficient torque as recommended by your battery manufacturer NOTE If you are using more than one battery you...

Page 39: ...of three conductor G L N cable allowing some extra length for connections and providing some slack 6 in 150 mm suggested 3 Unscrew the wiring compartment cover if not already from the previous step an...

Page 40: ...circuit breaker and the charger Figure 12 AC supply wiring 9 Secure cables in place using tie wraps or cable straps according to electrical codes 10 Tighten the cable glands if applicable 11 Replace...

Page 41: ...seven to ten second delay while the charger powers up NOTE Battery qualification may not be correctly performed if AC power is switched on first NOTE The onboard status LEDs will also illuminate mome...

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Page 43: ...maximum current However when AC input increases above 108 VAC up to 265 VAC maximum current returns to 100 capacity Furthermore the XPLORE Charger will continue to operate at 100 of maximum current Du...

Page 44: ...at a lower level to maintain the battery in a fully charged state If there is no load on the battery it will typically draw very little current The charger however is able to provide current to its f...

Page 45: ...l restart the charging cycle in the Bulk stage if the lowest battery voltage of the banks drops below 12 5 V 12 Vdc chargers for 15 minutes After 21 days the charger will automatically restart chargin...

Page 46: ...icable Table 4 Charging Maximum Voltages Battery Qualification The XPLORE Charger will perform a battery qualification on each application of AC or DC 9 V to determine if battery banks are present and...

Page 47: ...XPLORE 120 12 Battery Charger using the Xantrex BLE Module PN 808 0889 If you do not connect the BLE Module you can only configure the battery type for each battery bank using the Onboard Status LED...

Page 48: ...atus display will illuminate for a second power on test before reporting charging and battery status information You can configure the battery type for Group 1 or Group 2 using the Onboard Status LED...

Page 49: ...ptions of the different modes and settings of the XPLORE 120 12 Battery Charger This section includes Transitioning Power States 38 Charging Batteries 39 Equalizing Flooded Batteries 40 Using A Genera...

Page 50: ...Charger off Disable 1 Disconnect AC power at the source 2 Disconnect all DC batteries DANGER ELECTRICAL SHOCK HAZARD n Do not disassemble the battery charger Internal capacitors remain charged for fi...

Page 51: ...disconnect switches NOTE The onboard display LEDs will light up for a second 3 Ventilate the area around the battery thoroughly during charging Review the charging instructions supplied by the manufa...

Page 52: ...to require the user to continually re activate it as necessary after checking batteries manually but may not be sufficiently short to prevent battery damage In the following conditions the XPLORE Cha...

Page 53: ...r eye immediately flood it with running cold water for at least twenty minutes and get medical attention immediately To equalize your batteries NOTE All connected battery banks in each group will unde...

Page 54: ...ufacturer s specifications for specific gravity or until the specific gravity stabilizes relative to each other for an hour 6 The charger automatically exits equalization to float no float mode or res...

Page 55: ...ve rather than the true sine wave that the power utility provides If a generator needs to run on full load capacity to supply charging current to the battery via the battery charger its output frequen...

Page 56: ...This page is intentionally left blank 2...

Page 57: ...7 TROUBLESHOOTING This section will help you narrow down the source of any problem you encounter This section includes Maintaining the Charger 46 Troubleshooting 47 975 1038 01 01 45...

Page 58: ...tact with liquids spray or fumes which may cause corrosion and by keeping the air intake vent clean and free from any obstructions n Disconnect all AC and DC power and clean the outside of the case an...

Page 59: ...thin acceptable range Defective AC wiring or switches breakers Wiring and wiring components must be inspected and replaced by a qualified installer Symptom The initial power up display test is not per...

Page 60: ...tall in a cooler location Using the Xantrex App you may reduce the output current using the Max Charging Current setting If battery is too cold allow batteries to warm up Symptom XPLORE Charger comple...

Page 61: ...ge Disconnect all loads or switch loads off Battery has a damaged cell or has reached the end of its useful life Replace battery The Max Charging Current setting is too low for the battery capacity In...

Page 62: ...battery type can be equalized Not all batteries are fully charged The charger will wait for all batteries to be in float stage of three stage charging or rest stage of two stage charging before attem...

Page 63: ...O PROVIDE GENERAL AND NON EXACT INFORMATION ABOUT THE XPLORE 120 12 BATTERY CHARGER UNDER NO CIRCUMSTANCES SHOULD THIS STATUS DATA BE USED FOR PRECISE EVALUATION OF THE XPLORE CHARGER SYSTEM PERFORMAN...

Page 64: ...es mm 165mm 6 5 16 3 413mm 12 6 321mm 9 6 243mm 10 2 258mm 0 2 5mm 11 2 285mm BLE Module Unit dimensions L 0 97 in 24 8 mm W 2 95 in 74 8 mm with flanges 2 78 in 70 7 mm with hole center H 1 98 in 50...

Page 65: ...n phosphate or Custom Battery bank sizeb 600 Ah Number of diode isolated battery bank outputs 6 separated outputs DC battery output voltage range including dead battery charging voltage 0 16 VDC Maxim...

Page 66: ...adds in series with recommended 3 limit for user s battery cable voltage drop Protection Features XPLORE 120 12 Battery Charger Over voltage limits The XPLORE Charger will stop charging if the output...

Page 67: ...tery Temp Sensor BTS with 25 ft cable PN 808 0232 01 Regulatory Approvals XPLORE 120 12 Battery Charger Safety NRTL listed to CSA C22 2 No 107 2 UL1236 with marine supplement UL1564 and ABYC E 11 A 31...

Page 68: ...975 1038 01 01 Rev A 30996 http www xantrex com 1 800 670 0707 1 408 987 6030 Printed in...

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