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Xantrex XPLORE 120A 12V Owner'S Manual Download Page 36

Installing the XPLORE 120A 12V Battery Charger

22

XPLORE 120/12 Battery Charger Owner's Guide

Installing the XPLORE 120A 12V
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 on page 12

.

DANGER

ELECTRICAL SHOCK HAZARD

Disconnect all sources of AC mains and DC power before
proceeding.

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

Summary of Contents for XPLORE 120A 12V

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

Page 2: ...E 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: ...lved 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 http www xantrex com...

Page 5: ...the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure The addition of either symbol to a Danger or Warning safety label indicates that...

Page 6: ...rdous situation which if not avoided could result in minor or moderate injury NOTICE NOTICE is used to address practices not related to physical injury Figure 1 Product rating label sample NOTE Actual...

Page 7: ...een 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 reasse...

Page 8: ...or Lithium 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 bat...

Page 9: ...and dc 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 PO...

Page 10: ...NEGATIVE BLACK charger clip to free end of cable e Do not face battery when making final connection f When disconnecting charger always do so in reverse sequence of connecting procedure and break fir...

Page 11: ...irective CAN ICES 3 B NMB 3 B CAUTION Unauthorized changes or modifications to the equipment could void the user s authority to operate the equipment End of Life Disposal The XPLORE 120A 12V Battery C...

Page 12: ...This page is intentionally left blank 2...

Page 13: ...ts 18 Configuring Charge Current for Battery Size 21 Installing the XPLORE 120A 12V Battery Charger 22 Installation Sequence 23 Battery Operation 33 Input Voltage Operating and Derating 33 Dual Chemis...

Page 14: ...ing the Charger 48 Troubleshooting 49 Specifications 53 Physical Specifications 54 Environmental Specifications 54 AC Input Specifications 55 DC Output Specifications 55 Protection Features 56 Accesso...

Page 15: ...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 16: ...ard battery type selection n programmable charge settings for a Custom battery type n universal input AC line mains voltage ranging from 80 270 VV 50 60Hz n automatic charge resumption after AC mains...

Page 17: ...ting 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 expan...

Page 18: ...This page is intentionally left blank 2...

Page 19: ...ction identifies the default settings and the hardware features of the XPLORE 120A 12V Battery Charger This section includes Front Panel 6 Terminals and Ports 7 Onboard Status LED Panel 8 Accessories...

Page 20: ...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 21: ...up 2 40A total 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 con...

Page 22: ...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 23: ...8 01 01 9 Accessories This section lists all available accessories for the XPLORE 120A 12V Battery Charger To order contact Xantrex or your authorized dealer Battery Temp Sensor BTS with 7 6m 25 ft ca...

Page 24: ...This page is intentionally left blank 2...

Page 25: ...ng Requirements 18 Configuring Charge Current for Battery Size 21 Installing the XPLORE 120A 12V Battery Charger 22 NOTICE GENERAL PRECAUTION If parallel stacking two XPLORE Chargers to increase charg...

Page 26: ...ns in the USA Applicable codes in Europe are the IEC EN 60364 X Y series of standards DANGER HAZARD OF ELECTRIC SHOCK EXPLOSION BURN OR ARC FLASH n Apply appropriate personal protective equipment PPE...

Page 27: ...ull installation with six batteries and an AC mains source connection It also shows the AC and DC wiring and protection devices required for a safe installation Means of over current protection and di...

Page 28: ...for Europe G Connection to vessel chassis B AC mains source terminals G PE L N protected by fuses H Battery cable neg C Battery positive terminals for BAT3 through BAT6 Group 2 I Battery cable pos D...

Page 29: ...wire and breaker or fuse n a properly rated circuit breaker or a DC fused disconnect for each battery n four pieces mounting screws 10 M4 corrosion resistant Length dependent on mounting surface Loca...

Page 30: ...he installation of additional drip protection They are only acceptable for use in locations that are always dry The environment therefore will determine the mounting orientations that are suitable for...

Page 31: ...eck 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 orientation n Horiz...

Page 32: ...aker disconnects are correctly sized Maximum continuous DC current available from the charger may be an additional 6 10 above the nominal current rating of the charger DC Equipment Grounding The equip...

Page 33: ...se Sizes versus Wire Sizes AC Wiring DANGER FIRE HAZARD Use only on circuits provided with 20A maximum branch circuit protection in accordance with local and national electrical codes Failure to follo...

Page 34: ...mples of AC wiring requirements Conductors and flexible cords shall be stranded copper for the marine environment The AC mains wiring supplying the XPLORE Charger must be protected by the correct size...

Page 35: ...A 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 charger will charge...

Page 36: ...ions 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 Pre...

Page 37: ...ed to ensure safety in the presence of condensation Other possible mounting orientations will not prevent the entry of dripping water and are not suitable for use in moist environments WARNING HEAT HA...

Page 38: ...ng use all mounting holes in the mounting brackets and fasten all the screws Step 2 Connecting the DC Equipment Ground Earth WARNING ELECTRIC SHOCK HAZARD n Never operate the XPLORE Charger without pr...

Page 39: ...one or more yellow stripes or larger Make sure to tighten the bolt on the ground lug to a torque of 23 in lb 2 6 N m of force Apply an anti corrosion compound to the copper wire prior to connecting t...

Page 40: ...e extra length for connections and to provide slack in the wires for strain relief 2 Identify the positive cables by using color coded wire or by marking both ends of the cable with colored tape or si...

Page 41: ...ons See note below Failure to follow these instructions can result in equipment damage NOTE Make sure the positive terminals of the XPLORE Charger will be connected to the correct terminal of the DC c...

Page 42: ...rminal stacking Terminal stacking 1 2 3 5 4 1 flare nut 2 ring connector 3 terminal 4 cable 5 knockout cable gland Figure 13 Polarity connections common neg pos group 2 pos group 1 8 Connect the posit...

Page 43: ...ated prior to making this connection Failure to follow these instructions will result in death or serious injury 13 Secure cables in place using tie wraps or cable straps according to electrical codes...

Page 44: ...t the G PE L N wires to the XPLORE Charger AC terminal by lifting the clamp lever inserting the ferrule tip and pushing the lever down and securing the ferrule tip with the clamp see Figure 14 Method...

Page 45: ...wiring compartment cover WARNING ELECTRICAL SHOCK HAZARD n Replace the wiring compartment cover before turning on power to this equipment n Use a torque screwdriver to tighten both the captive nut pa...

Page 46: ...s normal to see a 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 als...

Page 47: ...maximum current However when AC input increases above 108 VV up to 265 VV maximum current returns to 100 capacity Furthermore the XPLORE Charger will continue to operate at 100 of maximum current Dual...

Page 48: ...e 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...

Page 49: ...ll restart the charging cycle in the Bulk stage if the lowest battery voltage of the banks drops below 12 5 V 12 VZ chargers for 15 minutes After 21 days the charger will automatically restart chargin...

Page 50: ...ble Table 5 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 he...

Page 51: ...XPLORE 120A 12V 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 52: ...status 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 L...

Page 53: ...tions of the different modes and settings of the XPLORE 120A 12V Battery Charger This section includes Transitioning Power States 40 Charging Batteries 41 Equalizing Flooded Batteries 42 Using A Gener...

Page 54: ...er off Disable 1 Disconnect AC mains 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 55: ...connect 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 manufactur...

Page 56: ...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 57: ...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 58: ...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 59: ...e 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 frequenc...

Page 60: ...This page is intentionally left blank 2...

Page 61: ...7 TROUBLESHOOTING This section will help you narrow down the source of any problem you encounter This section includes Maintaining the Charger 48 Troubleshooting 49 975 1038 01 01 47...

Page 62: ...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 mains and DC power and clean the outside of the case a...

Page 63: ...ut and it is within 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...

Page 64: ...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 65: ...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 66: ...LD Only this 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...

Page 67: ...IMATE VALUES INTENDED TO PROVIDE GENERAL AND NON EXACT INFORMATION ABOUT THE XPLORE 120A 12V BATTERY CHARGER UNDER NO CIRCUMSTANCES SHOULD THIS STATUS DATA BE USED FOR PRECISE EVALUATION OF THE XPLORE...

Page 68: ...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 3 mm Cable length 25 ft 7 6 m C...

Page 69: ...Output Specifications XPLORE Charger Battery typesa Flooded GEL AGM LFP lithium iron phosphate or Custom Number of diode isolated battery bank outputs 6 separated outputs DC battery output voltage ra...

Page 70: ...arger output terminals adds in series with recommended 3 limit for user s battery cable voltage drop Protection Features XPLORE Charger Over voltage limits The XPLORE Charger will stop charging if the...

Page 71: ...EC 55014 1 EN IEC 55014 2 EN IEC 61000 3 2 and EN IEC 61000 3 3 Environmental CE marked for Restriction of certain Hazardous Substances RoHS Directive 2011 65 EU and amending Directive EU 2015 863 com...

Page 72: ...975 1038 01 01 Rev C 31021 http www xantrex com 1 800 670 0707 1 408 987 6030 Printed in...

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