Xantrex Technology LINK 10 User Manual

i4.25

Xantrex Link 10 Battery Monitor

Link 10

Owner's Manual

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 November 2002, Revision 1 Part Number 445-0195-01-01 Contact Information

Web: www.xantrex.com

Email: CustomerService@xantrex.com

Phone: 1 800 670 0707 (toll free in North America)

1 604 422 2777 (direct)

Fax: 1 604 420 2145

Table of Contents

DO NOT INSTALL OR USE THIS PRODUCT UNTIL YOU HAVE READ THE ENTIRE OWNER’S MANUAL. IMPROPER INSTALLATION OF THIS UNIT MAY BE HAZARDOUS AND VOIDS YOUR WARRANTY.

Quick Reference Guide..................................................................................................5–6

Introduction.........................................................................................................................7

Battery Basics.....................................................................................................................8

Installation......................................................................................................................9–15

Startup................................................................................................................................16

Synchronizing the Link 10................................................................................................17

Operation......................................................................................................................18–24

Setting Battery Capacity....................................................................................................21

Temperature Sensor (optional)...........................................................................................25

Setting Peukert's Exponent...............................................................................................26

Low Battery Alarm.................................................................................................27, 35–38

Reset and Lock...................................................................................................................28

Historical Data...................................................................................................................29

Advanced Functions.....................................................................................................30–34

Peukert’s Equation.......................................................................................................39–42

Troubleshooting.................................................................................................................43

Options and Versions.........................................................................................................44

High Voltage Prescaler (optional)......................................................................................45

Electric Vehicles...........................................................................................................46–47

Lift Truck Installations......................................................................................................48

Serial Port, RS-232 (optional)............................................................................................49

High Voltage Notes............................................................................................................50

CE Declaration of Conformity..........................................................................................51

Limited Warranty..........................................................................................................52–54

Index...................................................................................................................................58

Specifications.....................................................................................................................59

Basic Wiring Diagram

The Xantrex Link 10 works with flooded or gel lead-acid batteries

Twisted pair wire is used for shunt sensing leads for noise immunity.

Battery Compartment

The 500 A 50 mV shunt senses current in or out of your battery.

SYSTEM POSITIVE

SYSTEM NEGATIVE

2 amp

Fuses

Meter Location

Top Rear View of Meter

-DC Meter Negative (BLACK) [1]

Shunt Sense Lead Load Side (GREEN) [2]

Shunt Sense Lead Battery Side (ORANGE) [3]

Battery Volt Sense (0–50 V DC1) (BLUE) [4] +DC Meter Power (9.5–40 V DC) (RED) [5]

Optional Temperature Sensor Input [6]

Optional Low Battery Alarm [7]

Optional Temperature Sensor Ground [8]

Quick ReferenceQuick Reference

Quick Reference

Quick ReferenceQuick Reference

The Light Bar

The light bar shows state-of-charge at a glance.

Here's what the lights mean:

EMPTY

Status Lights

Shows what number is

FULL

Full

80–99%+

60–79%+

40–59%+

20–39%+

0–19%+

For shortest charging times, lead acid battery in marine or

being displayed

The Button

When you press the button, you SELect a numeric display. In normal

operation, each press illuminates a status light. The being displayed, the amps, indicates time. We’ll explain these terms on the next page.

indicates amp hours, and

light indicates volts are

light indicates

RV service is normally discharged 50% then recharged to 85–90% of full. Restoring the last 10–15% of a full charge requires a long time—typically 2–3 hours. This means only 35–40% of your battery capacity is actually available for normal use. Occasionally discharging a battery more deeply is perfectly acceptable.

Quick Reference

Amps

Amps is the present flow of current in or out of your battery. For example, a refrigerator may draw 6.2 amps of current. This is displayed as amps are being con- sumed).

-06.2-06.2

-06.2 (6.2

-06.2-06.2

Volts

Volts is electricity’s poten- tial to do work. Voltage

helps assess approximate state-of-charge and to check for proper charging. A 12 V battery is considered 100% discharged when it drops below 10.5 V.

Advanced Functions

Press and hold the SET button for 3 seconds to enter the Setup and Advanced Functions mode. SEL

Amp hours

Amp hours consumed represents the amount

of energy removed from the battery. If you

run a 10-amp load for one hour, the Link 10 will show -10.0 in the display.

Time

Time is an estimate of how long your battery will sustain a load. A Time display of 3.7 hours means you have approximately 3 hours 42 minutes of operating

Setup Features

Locks front panel.

Shows charging efficiency and historical data.

Resets amp hours (

ALLALL

(

ALL) defaults.

ALLALL

AHAH

AH) or

AHAH

ap pears in the display.

Advanced

Functions:

Customizes the

Link 10's functions.

For details read

pages 29–30 and

pages 34–37.

time remaining.

Key Advanced Functions

F01 Scanning F02 Sleep Mode F09 Discharge Floor F15 S/WVersion F17 Test Lights

Introduction

Congratulations! The Xantrex Link 10 is the most advanced (Patents Pending) DC power measurement instrument available. It shows you:

Battery State-of-Charge on a multicolor light bar.

System voltage accurate to 1/20th of a volt (

System current accurate to 1/10th of an amp (

Amp hours removed from, or put into, your battery.

Time of operation remaining until recharging is required.

For installation and operation questions, please contact Xantrex at 1-800670-0707 (toll free) or 1-604-422-2777 (direct). You can also email Xantrex at CustomerService@xantrex.com. For warranty and technical support please follow the process outlined on page 52.

If you wish the Link 10 to support an external Low Battery Alarm, such as a bell or buzzer, or if you need the Link 10 to report data to a computer or data logging unit, these options must be included at the time of manufac-

<20 VDC).

<40 amps).

ture and cannot be retrofitted in the field.

The installation of the Link 10 is simple, as is its operation. However, there are many advanced features and functions, so please take the time to read and thoroughly understand this manual.

Installer's Note: This manual contains operating

instructions. Please leave it with the meter!

Battery Basics

Why monitor a battery?

Batteries can be ruined by excessive discharge. They may also be damaged by under-charging. A battery (or bank of batteries) may be storing less energy than you think. The Link 10 provides all the key data you, or your technician, need to make decisions about battery use and charging.

How does the Link 10 work?

The Link 10 uses sophisticated microprocessor technology to report all significant battery information. The Link 10 monitors battery voltage and current over time to report amp hours consumed and time remaining— precisely the information necessary to maximize system performance.

What's an amp hour?

Batteries are rated by amp hour capacity. A battery that delivers one amp for one hour has delivered one amp hour. Marine and RV deep-cycle battery capacity is based on their 20-hour discharge rate. A battery that delivers 10 amps to a load for 20 hours before battery voltage drops to 10.5 volts, is considered a "200 amp hour" battery. 10 amps times 20 hours equals 200 amp hours (200 Ah).

For maximum life you should never discharge more than half the rated capacity of a battery. Therefore, if you have a 200 amp hour battery, you should recharge when the Link 10 shows -100 in the amp hour display. The

-100 means 100 amp hours have been removed from your battery.

FOR MAXIMUM BATTERY LIFE, RECHARGE YOUR

BATTERIES WHEN YOU HAVE DISCHARGED 50%

OF THEIR AMP HOUR CAPACITY.

Installation

Basic installation of the Link 10 on a 12 or 24 volt system involves only five wires. Because the Link 10 will work on systems up to 500 volts, special high voltage installation techniques are discussed beginning on page

44. You need to read this section if you're working on an electric vehicle or system where more than 50 volts is encountered. If your installation is on a 12 or 24 volt system, let's get to work!

Installation Planning

First, gather all the tools you'll need for installation. We recommend:

* A 2" or 2 1/16" (52 mm) hole saw to make the panel cutout. * A 3/8" drill with bits to run power and shunt wiring. * An adjustable 9/16" wrench for shunt bolt connections. * Wire stripper/crimper and a small flat blade screwdriver.

Make sure you have all the parts you'll need to complete the job:

* A 500 A–50 mV shunt (included) * #18 or #16 twisted pair shunt wire long enough to reach

from the battery to the meter location. Ask your dealer for Xantrex Technology PN 84-2014-00 - 25' 4 twisted pair cable or PN 84-2015-00 - 50' 4 twisted pair cable (not included).

* 2 in-line fuse holders with 2-amp fuses.

CAUTION: DO NOT INSTALL FUSES UNTIL YOU

COMPLETE INSTRUCTIONS ON PAGES 10–15.

* A short heavy-duty battery cable to run from one shunt bolt

to the battery. Cable is available at auto and marine shops.

* Assorted small-gauge crimp type terminals for connecting

the power, shunt, fuses, and voltage sense leads.

Mounting

12345

Our Patent Pending "Ratchet Ring" makes mounting easy and fast.

TIP: When installing from the front of a panel or dashboard slide the Ratchet Ring onto cable with correct orientation and then connnect the wires.

Push Ratchet Ring on until firmly in contact

CAUTION! Orient ring so the ratchet teeth will engage properly. Practice installing and removing ring before final assembly. Considerable force is required—this ensures the ring will not loosen over time.

Install the meter from the front of your panel. The panel thickness may range from 1/16" to 1 1/2". Slip the locking ring on

with panel.

PATENTED

from the rear and press forward until its teeth hold the meter securely in place.

The gasket around the ring of the Link 10 should provide an adequate seal against moisture. If a sealant is used be sure it is silicone so that the Link 10 may be removed without damage.

Removing

Removing the Link 10 is the reverse of mounting with a TWIST as shown in the following diagrams.

Twist 1/8th turn to unlock teeth.

Pull both sides of the lock ring equally

Then pull lock ring straight back as shown below.

PATENT PENDING

Patented

Wiring Overview

This drawing is for 12 V & 24 V systems. For higher voltages see Prescaler use on page 44.

Fuses

Shunt

DC+

DC-

Twisted pair cable

See Detail page 13

Terminal Strip

INSTALLATION TIP:

Connections

Use appropriate strain relief to

See Detail page 14

avoid damage to the connector and terminal strip on the rear of

Mounting Page 10

Removing page 11

TIP:

NOTE: To limit Voltage measurement error do not exceed wire lengths shown

For a neat and professional looking installation use plenty of:

* Nylon wire wraps * Wire wrap anchor points.

the Link 10.

(system ground)

below. Error assumes 16 AWG wire and max. power consumption.

0.5% Error 72 Feet Maximum

1.0% Error 150 Feet Maximum

3.0% Error 450 Feet Maximum

Shunt & Battery Wires

1234

The shunt is the current sensor for the Link 10. Its 500 A, 50 mV rating means that when 500 amps flows through it there is 50 mV generated across it. The millivolt signal is translated into an amps display in the Link

10. For example: a 50 A load would generate 5 mV across the shunt and would be displayed as

50 amps. Caution: in the diagram below, the darker

wires represent primary wiring and should be able to carry full battery

load current. Size appropriately!

SYSTEM POSITIVE

SYSTEM NEGATIVE

LOAD

LOAD SIDE

234567

2345678

SIDE

Connect NO other wires directly to battery negative! All current must flow through the shunt!

BATTERY

SIDE

500 A 50 mV

SHUNT

2345678

234

These wires

BLACK

ORANGE

must be a

twisted pair!!

GREEN

RED

BLUE

2345678901234567890123456789012123

4 Twisted pair cable. See page 14 for part numbers.

2345678901234567890123456789012123

2 amp Fuses (mount within 7" of battery)

Meter Wiring Detail

Make the necessary wire connections to the Link 10 as shown in the following diagram:

Color code shown for Xantrex 4 twisted pair cable. P/Ns below:

P/N 84-2014-00 -25' P/N 84-2015-00 -50'

Use correct sized screwdriver for terminal screws. Tighten firmly but do not over-tighten to avoid damage

Top Rear View

DC - Meter Negative (BLACK) [1]

Shunt Sense Lead Load Side (GREEN) [2]

Shunt Sense Lead Battery Side (ORANGE) [3]

Battery Volt Sense (0–50 V DC1)(BLUE) [4]

DC + Meter Power (9.5–40 V DC) (RED) [5]

Optional Temperature Sensor Input [6]

CAUTION

Optional Low Battery Alarm [7]

Optional Temperature Sensor Ground [8]

1) For Voltages above 50 V a Prescaler must be used. See page 44.

Wire by Wire Check

Most failures and problems are due to wiring errors. Please double check the wiring. (Color code shown is for Xantrex wire P/Ns on page 14.)

#1 - DC Power (Black Wire). Start at terminal #1 of the Link 10 and

follow it to the big bolt on the Load side of the shunt. Do not connect this

wire to the small screw terminal with the Green shunt sense lead.

#2 Shunt Sense Lead Load Side (Green Wire). This wire connects to

the small screw on the Load side of the shunt. twisted pair with the Orange wire described below. To check this wire start at terminal #2 and follow it to the small screw on the Load side of the shunt. There should be no other wires connected to this screw. NOTE: Also check the primary wiring from the shunt to the battery. There should be only one heavy cable from the Battery side of the shunt to the battery. All loads and sources must be connected on the other side of the shunt. Only the shunt may be connected directly to battery negative!

#3 Battery Side of Shunt (Orange Wire). This wire must be a twisted

pair with the Green wire described above. To check this wire start at

terminal #3 and follow it to the small screw on the Battery side of the shunt. There should be no other wires connected to this screw.

#4 Voltage Sense Wire (Bat.+) (Blue Wire). From terminal #4 this wire

This wire must be a

should run to a 2 amp fuse holder, located within 7" of the battery. The other side of the fuse holder should go to the positive (+) battery post. If Voltage is greater than 50 V, see High Voltage Prescaler, page 44.

#5 + DC Power (Red Wire). This wire should run from terminal #5 to a

2 amp fuse holder located within 7" of the battery. The fuse should not yet be installed. The other side of the fuse holder goes to the battery. If power supply voltage is above 24 V, see the Electric Vehicles section, page 46.

Startup

Once you have completed ALL instructions on page 15, insert the voltage sense wire fuse, then the meter power fuse. (BLUE wire fuse first, RED wire fuse last!) The fuse should be in a fuse holder and should be connected in a smooth motion. A "ragged" power-up may cause a meter lockup. Both the bar graph and digital display should come on.

Factory Default Settings

The Link 10 comes on in the (Volts) mode with the display flashing to indicate that it has been powered up from the de-powered state (see page

26). Left untouched for 10 minutes, the Link 10 will go to "sleep," turning off the digital display leaving only the bar graph on. (This is a powersaving feature.) Touching either the SEL or SET buttons will return the

Link 10 to the function the Link 10 was in when it went to "sleep."

The Link 10 is designed to work "out of the box." The factory default values are appropriate for a moderate capacity 12 V liquid lead acid battery and a typical user display and function setup. that must be made is setting the battery capacity. You may also have to set the appropriate Peukert's exponent for your battery (see page 26). Special functions and display options are described beginning on page 27.

Often the only change

The Link 10's Factory Default Settings Are:

1. Automatic Scanning of V, A, amp hours, and time will be OFF.

2. Sleep Mode is ON. Turns digital display off after 10 minutes.

3. Charge Efficiency Factor (CEF) equals 90% and learn CEF mode is on.

4. Charged Parameters: Voltage =13.2, Charged Current =2%. The battery must exceed 13.2 V and the current must be less, in amps, than 2% of declared capacity for five minutes for the Link 10 to consider the battery full.

5. Battery capacity set to 200 amp hours.

6. Peukert Exponent = 1.25.

Synchronizing the Link 10

Synchronize the Link 10 to a Full Battery

After installing the Link 10, charge the battery until the far right Green LED begins flashing, which indicates the Charged Parameters have been

met. Amp hours will have started at ber. As you begin discharging the battery, the LED will stop flashing and the numeric amp hour display resets to factory assuming a 200 amp hour battery. Your battery may be a different size. To change battery size, see page 21.

0 and counted up as a positive num-

0. The Link 10 is shipped from the

Staying in Sync, Removing Accumulated Negative Amp Hours

Should the Link 10 ever become out of sync with the battery state-ofcharge simply charge until the far right LED flashes Green. You may also get back in sync by charging until the battery is full and then resetting the amp hours to zero through the RESET function.

If the Link 10 should accumulate a negative number in the amp hour display you will have to charge until you meet the conditions for a recalculation of the Charging Efficiency (CEF) as described on pages 22 & 23. If you do not meet all five of the conditions listed below you will not get a recalculation of the CEF and a reset to zero amp hours consumed.

CONDITIONS TO RESET TO ZERO

1) Discharge 10% of declared battery capacity to trigger algorithm.

2) Recharge until 100% of the kWh removed have been returned.

3) The voltage must be above the Charged Voltage Parameter.

4) The current must be below the Charge Current Parameter.

5) Conditions 3 & 4 must be met for 5 minutes (1 min. for AE default)

Operation

Although the Link 10 is a very sophisticated device, obtaining basic battery information from it is simple. With the unit turned on and the (Volts) LED on, let's learn how to display the four most important DC system parameters.

When you touch the button, you are SELecting the display you wish.

Each time you touch SEL in normal operation, you will toggle to the next

i4.25

item to the right (amps) to (amp hours) to (time).

Now press SEL to bring up these functions.

Volts is the electric potential to do work. Voltage is useful to assess the approximate state-of-charge and to check for proper charging. Examples: An at-rest, fully charged battery will show about 12.8 V. A 12 V battery is 100% discharged when it reaches 10.5 volts with a 20-hour rated load applied. A typical charging voltage would be 14.2 V.

Amps is the present flow of current in or out of the battery. For example, a refrigerator may draw 6 amps of current. This is displayed as amps are being consumed). Discharge is shown as a negative number and charging is shown as a positive number (unsigned).

(volts) goes to

- 6.0 (6

Amp hours consumed represents the amount of energy removed from the battery. If you run a 10-amp load for one hour then ten amp hours are consumed. The Link 10 will show the Link 10 will compensate for charging efficiency and count back up toward 0.

Time is an estimate of how long (in hours) the battery will sustain a load. It is based on a selectable, time averaged, rate of discharge. Default is the average of the last four minutes of use (see page 24).

-I0 in the display. During charging

+ 42 hidden pages