Xantrex XPower Charger 15 Owner's Guide

XPower Charger 15 and 40

Owner’s Guide

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility -scale systems for wind, solar, bat teries, fuel cells, microturbines, and backup power applica tions in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, an d variable speed drives that conve rt, supply, control, cl ean, and distrib u t e el ec tr i cal power.

T rademarks

XPower Charger 15 and 40 are trademarks of Xantrex International. Xantrex is a registered trademark of Xantrex International.

Other trademarks, registered trademarks, and product names are the property of their respecti ve owners and are used herein for identification purposes only.

Notice of Copyright

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”)

(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER ’S RISK.

Date and Revision

April 2004 Revisi on A

Part Number

975-0147-01-01

Contact Information

Telephone: 1 800 670 0707 (toll free North Americ a)

1 360 925 5097 (direct)

Fax: 1 800 994 7828 (toll free North Americ a)

1 360 925 5143 (direct) Email: customerservice@xantrex.com Web: www.xantrex.com

About This Guide

Purpose

This guide introduces the XPower Charger 15 and 40, describes the features, explains how the XPower Chargers charge batte ries, and provides procedures for oper ating the chargers.

Scope

This guide provides inform ation for two products, the XPower Charger 15 and the XPower Charger 40 . Where information is specifi c to one product, that pr oduct i s refe rred to by name. When information applies to both products, they are referred to collectively as XPower Charger.

This guide does not provide details abo ut particu lar bran ds of batteries. You need to consult individual battery manufacturers for this information.

Audience

The Guide is intended for anyone who needs to install and operate the XPower Charger 15 and 40.

Organization

This Guide is organized into 4 chapters and 2 appendices: Chapter 1, “Introducti on”, Chapter 1 contains infor mation on

the features avail able and the location of important parts on the front panel of the XPower Charger 15 and 40.

Chapter 2, “Operation”, Chapter 2 explain s how to operat e the XPower Ch arger effic ie ntly to charge a vehi cle ba tte ry.

iii

About This Guide

Chapter 3, “Troubleshooting”, Chapter 3 will help you identify and remedy the common problems than can occu r with the XPower Charger.

Appendix A, “Specifications”, Appendix A lists the specifications for the XPower Charger.

Appendix B, “Battery Charging”, Appendix B describes battery char ging in more detail.

Conv en t io n s Used

The following conventions are used in this guide.

WARNING

Warnings identify conditions that could result in personal injury or loss of life.

CAUTION

Cautions ide ntify conditions or practices that could result in damage to the unit or to other equipment.

Important:

an item that you must pay attention to.

These notes describe an important action item or

Relat ed Inf o rmation

You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com

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Important Safety Instructions

The XPower Charger 15 and 40 generate a low DC voltage and high DC current to the battery being charged. Operating the XPower Charger 15 and 40 incorrectly or misusing them may damage the e quipment or crea te haz ardous co nditi ons for the user.

Save these instructions. This guide contains important safet y and operating instruc tions.

WARNING: Explosion hazard

The XPower Charger 15 and 40 are designed to charge 12 V leadacid batter ies only. Do not use these products on ba tteries with other voltage ratings.

WARNING: Shock hazard. Keep away from children.

The XPower Charger 15 and 40 generate a low voltage and high current DC to the battery being char ged. Do not expose the c harger to water, rain, snow or spray. Do not open the XPower Charger 15 an d 40. Th ere are no userserviceable parts inside the unit.

WARNING: Explosion hazard

Do not use this product where there are flammable fumes or gases, such as in the bilge of a gasoline-powered boat, or near propane tanks. Do not use thi s prod uct in an enclosure conta ining lead acid batteries. Thes e batt eries ve nt e xplos ive hydro gen gas whi ch can be ignited by sparks from electrical connections. When wo rking on elect ri c al equ i p men t , al w ay s ens u r e so meone is nearby to help you in an emergency.

WARNING: Explosion hazard

Battery rec onditioning mode works only on flooded lead-a cid 12 V batteries. Do not attempt to recondition sealed lead- acid batteries.

Safety

WARNING: Explosion hazard

During battery reconditioning phase , the battery generates potentially flammable gases. Follow all the battery safety precautions l ist ed i n this gu ide. Ventilat e the ar ea aro und t he bat tery thoroughly and ensure that there are no sources of flame or sparks in the vicinity.

WARNING: Heated surface

Ensure at least 2" (5 cm) air space is maintained on all sides of the XPower Charger 15 and 40. During operation, keep away from materials that may be affected by high temperatures.

WARNING: Explosion hazard

Never attempt to ch arge a frozen batte ry.

WARNING: Shock hazard

To reduce the risk of elec trical shock, disconnect both AC and DC power from the XPower Charger 15 and 40 before attempting any maintenance or cle aning or working on any circuits connected to the XPower Charger 15 and 40. Turning AC will not reduc e this risk.

ON/OFF switch to OFF

CAUTION

Do not expose the XPower Charge r 15 and 40 to temperatures over 104 °F (40 °C).

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Safety

Precautions When Working With Batteries

WARNING: Explosion or fire hazard

1. Follow all instructions published by the battery manufacturer and the manufacturer of the equipment in which the battery is instal led.

2. Make sure the area around the battery is well ventilated.

3. Never smoke or allow a spark or flame near the engine or batteries.

4. Use caution to reduce the risk or dr oppi ng a metal too l on the battery. It could spark or short circuit the battery or other electrica l parts and could cause an explosion.

5. Remove all metal items, like rings, bracelets, and watches when working with lead-ac id batteries. Leadacid batterie s produce a short circuit current high enough to weld metal to skin, causing a severe burn.

6. Have someone within range of your voice or close enough to come to your aid when you work near a leadacid battery.

7. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

8. Wear complete eye protection and clothing protection. Avoid touching your eyes while working near batteries.

9. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately.

10. If you need to remove a battery, always remove the ground terminal from the batte ry first. Make sure all accessories ar off so you don’t cause a spark.

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Safety

FCC Information to the User

This equipment has been teste d and found to comply wit h the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against ha rmful interference in a residential installati on. This e quipment generates, uses and can radiat e radio frequency energy and, if not installed and used in accordance with the inst ruction guide, may cause harmful interference to radio communications. Operation of this equipment in a residentia l are a is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

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Contents

Important Safety In str uctions 1

Introduction

XPower Charger Features - - - - - - - - - - - - - - - - - - - - - - - - - -1-1

Continuous Charge Rating - - - - - - - - - - - - - - - - - - - - - - -1-2 Wide Voltage Range - - - - - - - - - - - - - - - - - - - - - - - - - - -1-2 Protection Features - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-2 Isolated Design- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-3 Front Panel Selectors- - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3

Front Panel Indicator Lights and Settings - - - - - - - - - - - - - - - -1-4

Charger Cable Storage Compartment - - - - - - - - - - - - - - - - 1-6

Operation

Operating Condition s and Guidelines - - - - - - - - - - - - - - - - - -2-1 Choosing a Location- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-2 Charging 12 Volt Batteries- - - - - - - - - - - - - - - - - - - - - - - - - -2-3

Charging Rat e s Se lect ion Gu ide - - - - - - - - - - - - - - - - - - -2 -5

Reconditioning (Equalizing) Flooded Type Batteries - - - - - - - - 2-6

- - - - - - - - - - - - - - - - - - - - v

Troubleshooting

Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - -3-1

Specifications

Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - A-1 Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - A-2 AC Input Specification s - - - - - - - - - - - - - - - - - - - - - - - - - - A-3 Protection Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A-3 Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A-3

Contents

Battery Charging

Bulk Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B-1 Absorption Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B-1 Float Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B-2 Calculating External Battery Charging Time- - - - - - - - - - - - - B-3 Battery Reconditioning Mode- - - - - - - - - - - - - - - - - - - - - - - B-4

About Reconditioning - - - - - - - - - - - - - - - - - - - - - - - - - B-5

Warran ty and Return Information

- - - - - - - - - - - - -WA-1

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Introduction

Chapter 1 contains infor mation on the features available and the location of important pa rts on the front panel of the XPower Charger 15 and 40.

XPower Charger Features

The XPo wer Ch a rgers are advanced batter y chargers designed specific ally for high performance, deep-cycl e leadacid engine batte ries. They are smaller and lighter tha n many other charge rs.

XPower Charger changes the alternatin g current (AC) supply from the utility to the controlled low-voltage, direct current (DC) required to char ge a 12 V battery by using highfrequency, switching-mode power conversion circuits. The high-frequency power conversion method is similar to that used in power supplies for computer s and other electronic equipment. It results in a significantly smaller and ligh ter charger than other power c onversion methods allow.

The XPower Charger has AC to DC isolation, a surge protector, and many other safety features which reduce potential shock and fir e hazar ds.

1-1

Continuous Charge Rating

The XPower Charger 15 delivers 2/8/15 amp charging current. The XPower Charger 40 delivers 2/20/40 amp charging curr ent. Traditional (low frequency) char gers only deliver their rate d char ging current for a short initial part of the charge cycle. The XPower Charger only reduces the charging current below these rated levels when the battery is approaching full charge. Because it delivers rated current over most of the charge cycle, XPower Charger charges your batteries fast er than many other chargers with the same or higher rating.

Wide Voltage Range

XPower Charger maintains the correct charging voltage for your battery when the AC line voltage drops as low as 104 VAC or rises as high as 127 VAC. A surge protector in XPower Charger protec ts i t from surg es and spik es on th e AC power line.

Protection Features

XPower Charger provide s the following protection featur es:

• Overheating protection

• Reverse polarity warning indicator light

• Overvoltage protection

• Bad battery indication

• Over current protection

• Charging time out protection

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Isolated Design

The DC battery charging circuits of XPower Charger are galvanically isolated by a transformer from the AC power circuits. This feature reduces the risk of electric shock and helps to prevent corrosion in marine applications.

Front Panel Selectors

Display Selection

The Display Selection push butt on allows you to toggle the display to show the vehicle batt ery voltage and charging current during the charging mode. The display indicates the battery capacity when the AC is not plugged in.

Charge Rate

The Charge Rate push button al lows you t o select t he optimal charge current for your battery. Refer to Table 2-3 and Table 2-4 on page 2-5 for appropriate charge rate selections.

Battery Reconditioning

The Battery Reconditioning push button (pin-hole type) allows you to recondition a bad flooded battery that does not accept charge.

XPower Charger Features

975-0147-01-01 1-3

Front Panel I ndicator Lights and Settings

This section describes the parts of the XPower Charger. Figure 1-1 shows the front panel. Descriptions are provided in the table.

Figure 1-1

Panel Item Description

1 Digital Display displays the numerical value of the

2 Incorrect Connection l ight, under the Bat tery Charger

3 Charging Error light illuminates when a fault condition

XPower Charger Front Panel

(XPower Charger 15 shown)

battery voltage, charging current and capacity. The Volts (V), Current (A), Battery % lights indicate which condition is being reported. The digital display is also used to indicate error codes when Charging Error light (Item 6) is illuminated. See Chapter 3, “Troubleshooting”.

section, illuminates when a revers e polarity is detecte d at the charging cable.

is detected.

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