Xantrex Technology Link 1000 User Manual

Link 1000

Owner’s Guide

About Xantrex

Xantrex Technology develops, manufactures, and markets advanced power electronic products. The company’s products convert raw electrical power from any source into high-quality power required by electronic and electrical equipment.

Trademark

Xantrex is a registered trademark of Xantrex International Other trademarks, registered trademarks, and product names are the property of

their respective owners and are used herein for identification purposes only.

Notice of Copyright

Link 1000 Owner’s Guide © July 2003 Xantrex International. All righ ts res erv ed.

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

July 2003, Revision A

Part Number

975-0056-01-01

Contact Information

Web: www.xantrex.com Email: CustomerSupport@xantrex.com Phone: 1-800-670-0707 (toll free in North America) 1-604-422-2777 (direct) Fax: 1-604-420-2145

Contents

1 Introducing Link 1000

Introducing the Link 1000- - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

Inverter/Charger Control Functions - - - - - - - - - - - - - - - - - - - - 2 Monitoring F unctions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

Reading the Link 1000 Control Panel - - - - - - - - - - - - - - - - - - - - 4

Where to go Fr om Here - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

2 Installing the Link 1000

Planning the Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

Supplied Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 Materials You Need to Supply - - - - - - - - - - - - - - - - - - - - - - 8 Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Installatio n Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 Color-Coded Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - 10 Twisted Pair Wires - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10 Separate Engine Starting Battery - - - - - - - - - - - - - - - - - - - 1 0

Installing the Link 1000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

Overview of Installation Steps - - - - - - - - - - - - - - - - - - - - - - 11 Mounting the Link 1000 Control Panel- - - - - - - - - - - - - - - - - 13 Mounting and Cabling the Shunt - - - - - - - - - - - - - - - - - - - - - 14 Wiring the Terminal Block - - - - - - - - - - - - - - - - - - - - - - - - - 15 Connecting Terminal Block Wires to Shunt and Battery - - - - - 16 Installing Fuses- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17 Connecting the Phone Cable - - - - - - - - - - - - - - - - - - - - - - - - 17 Testing the Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

iii

Contents

Maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18 Disconnecting the Inverter/Charger - - - - - - - - - - - - - - - - - - - 18

3 Setting up the Link 1000

About Link 1000 Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - 20

Probable Changes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20 Possible Changes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20 Other Settin gs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20

How to Enter Setup Mode and Change a Value - - - - - - - - - 20 Locking Your Setup Values - - - - - - - - - - - - - - - - - - - - - - - - 21 Resetting Values- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21 Battery Capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

Estimated Capacities for 12 Volt Flooded Batteries - - - - - - - 22

Estimated C apacities for G el Cell Batteri es - - - - - - - - - - - - 22

Estimated Capacities for Multiple Batteries - - - - - - - - - - - - 22

Changing th e Battery Capacity Setting - - - - - - - - - - - - - - - 23

Changing th e Battery Type S etting - - - - - - - - - - - - - - - - - - 23

Changing the Ambient Temperature Setting - - - - - - - - - - - 24 Charged Par ameters- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

Changing th e Charged Volta ge Setting - - - - - - - - - - - - - - - 25

Changing the Charged Current Percentage Setting - - - - - - - 25

Changing th e Time Remaining Setting - - - - - - - - - - - - - - - 26

Changing the Power Share Setting - - - - - - - - - - - - - - - - - - 2 7

Changing the Idle Mode Settin g - - - - - - - - - - - - - - - - - - - - 28 Advanced F unction Values - - - - - - - - - - - - - - - - - - - - - - - - - 29

How to Enter Setup Mode and Change a Value: Reminder - - 29

F01 Auto Display Scanning - - - - - - - - - - - - - - - - - - - - - - 29

F02 Display Sleep - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

F03 Set or Display Ambient Battery Temperatures - - - - - - - 30

F04 Toggle Display Between Ah and kWhr - - - - - - - - - - - - 30

F05 Turn on Alternative Energy Mode - - - - - - - - - - - - - - - 31

F06 Manually Set CEF - - - - - - - - - - - - - - - - - - - - - - - - - - 31

F07 Set Temperature Coefficient - - - - - - - - - - - - - - - - - - - 31

F08 Set Peukert’s Exponent - - - - - - - - - - - - - - - - - - - - - - 32

F09 Set Low Battery Discharge Floor - - - - - - - - - - - - - - - - 32

F10 Select B attery Type - - - - - - - - - - - - - - - - - - - - - - - - - 33

F11 Turn on Second Battery Voltage Sense - - - - - - - - - - - - 33

F12 Number of Overload Conditions Experienced - - - - - - - 33

F13 Number of Inverter Low Battery Shutdowns - - - - - - - - 33

F14 Test Control Panel Display - - - - - - - - - - - - - - - - - - - - 34

F15 Display Software Revis ion Number - - - - - - - - - - - - - - 34

F16 Turn on Active Temperature Compensation - - - - - - - - 34

4 Using the Link 1000

Monitoring F unctions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36

Choosing a Display Unit: Volts, Amps, Ah, or Time- - - - - - - - 36 Reading the Battery State-of-Charge - - - - - - - - - - - - - - - - - - 37

Scaling the BATTERY STATUS Light Bar - - - - - - - - - - - - 37

Inverter Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38

Turning on the Invert Func tion - - - - - - - - - - - - - - - - - - - - - - 38 Changing the Idle Mode Settin g - - - - - - - - - - - - - - - - - - - - - 38

Charging Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39

Summary of C HARGER STATUS LEDs - - - - - - - - - - - - - - 39 Charging th e Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 0 Equalizing the Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - 40

Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40

Equalizing G el Cell Batteries - - - - - - - - - - - - - - - - - - - - - 42 Activating Power Share - - - - - - - - - - - - - - - - - - - - - - - - - - - 42 Battery Capacity Testing - - - - - - - - - - - - - - - - - - - - - - - - - - 42 Synchronizing the Link 1000 to the Battery- - - - - - - - - - - - - - 44

Over-charge Ah (Accumulation of Positive Ah) - - - - - - - - - 45

Battery History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46

Interpreting Battery History - - - - - - - - - - - - - - - - - - - - - - 46

Reading Error Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48

Contents

A Specifications

Control Pan el: Electrical Specifications- - - - - - - - - - - - - - - - - - 52 Control Panel: Physical Specifications - - - - - - - - - - - - - - - - - - 52 Default Settings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

Product and System Information

Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56 Disclaimer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

Product - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Warning: Lim itations On Use - - - - - - - - - - - - - - - - - - - - - - - 59

Return Mater ial Authorizatio n Policy - - - - - - - - - - - - - - - - - - - 59 Return Material Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - 59 Product Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60 Record of System Settings - - - - - - - - - - - - - - - - - - - - - - - - - - 61

Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63

Figures

Link 1000 Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 System Overview (Wiring)- - - - - - - - - - - - - - - - - - - - - - - - - 12 Display Panel and Mounting Plate - - - - - - - - - - - - - - - - - - - - 13 Link 1000 Mounting Plate - - - - - - - - - - - - - - - - - - - - - - - - - -14 BATTERY STATUS Light Bar - - - - - - - - - - - - - - - - - - - - - 37

vii

viii

Introducing Link 1000

Chapter 1 describes:

• The Link 1000’s control and monitoring functions

• The features on its control panel

Introducing the Link 1000

The Link 1000 gives you complete remote control of the Freedom 458, Freedom, and Freedom Marine Inverter/ Chargers. It also lets you monitor the performance of your battery power system.

Inverter/Charger Control Functions

From the Link 1000 control panel, you can:

• Turn the invert function on and off

• Start or end an equalization cycle

• Activate the Power Share feature. This automatically lowers the charger’s output to prevent AC breakers from tripping if too many loads come on at once.

• Place the inverter/charger in Idle (standby) mode so it only begins inverting at a level that you choose. This power-saving feature minimizes t he draw on you r batter y by turning the inverter off until it’s really needed.

• Make custom settings for numerous functions including battery type, battery capacity, and Power Share mode. These let you set up the Link 1000 so it suits the characteristics of your system.

• Lock your setup values so no one can inadvertently change them

Monitoring Functions

The Link 1000 control panel lets you see:

• The battery’s state-of-charge at a glance

• The voltage of the battery being monitored and the voltage of a second (starting) battery

• The flow of current into the battery (charge rate)

• The flow of current out of the battery (consumption rate)

• The number of Ah (Amp-hours) that have been consumed

Introducing the Link 1000

• The time remaining in your battery before it is completely discharged

• Which charging stage the batteries are in (Bulk, Acceptance, Float, or Equalization)

• Battery history including:

• Present charge efficiency

• The number of deep cycles the battery has had

• The deepest level of discharge

• The average level of discharge

Reading the Link 1000 Control Panel

The Link 1000 control panel lets you monitor the battery system and control the inverter/charger. Its features are described below. Further details are provided as you need them throughout the guide.

Figure 1 Link 1000 Control Panel

BATTERY STATUS light bar

When the battery system is operating, the four LEDs in this light bar act like a “fuel gauge”. The LEDs light in different sequences and colors to show the battery’s present state-of-charge. The statuses are described on page 37.

Reading the Link 1000 Control Panel

2, 3 Numeric display and display units.

You can choose from four display un its depending on the type of information you want to see:

• Volts

•Amps

• Ah (Amp-hours)

• Time Remaining The procedure for changing display units is given on

page 36 along with an explanation of each display unit.

Note

: The numeric display also shows Error Codes. If

an error occurs, the display alternates between the monitoring function you have selected and the Error Code. For details about Error Codes, see page 48.

SEL and SET buttons SET lets you access Setup mode and advanced

functions. Once you are in Setup mode, you press

SEL to choose a function or a setting . Procedu res for

changing values are given in Chapter 3.

5 CHARGE/PWR SHARE button and LED

Lets you start a charge cycle (see page 40) or change the Power Share mode setting (see page 27).

INVERT/IDLE MODE button and LED

Lets you activate the invert function (see page 38) or change the Idle mode setting (see page 28).

RESET, DATA, LOCK, FUNC LEDs

•

RESET: When it is on, this LED indicates that you are

resetting Ah (Amp-hours) to zero or that you are returning all settings to the factory defaults. (See

page 21.)

•

DATA: Indicates that you are looking at historical

information about your batteries. (See “Interpreting

Battery History” on page 46.)

•

LOCK: Indicates you are choosing the setting that

prevents people from inadvertently changing your setup values. (See page 21.)

•

FUNC: Indicates you are accessing the advanced

functions. (See “Advanced Function Values” on

page 29.)

Reading the Link 1000 Control Panel

8 AC IN LED

Indicates that AC power is present.

9 CHARGER STATUS LEDs:

•

CHG (Red): When this LED is on solid, the battery is

in Bulk charge mode. When this LED is flashing, the battery is equalizing.

•

ACCEPT (orange): The battery is in Acceptance

mode.

•

FLOAT (green): The battery is in Float mode.

Where to go From Here

• To install the Link 1000, see page 7.

• To set up the Link 1000, see page 19.

• To use the Link 1000, see page 35.

• To call for technical support, see page 56.

Installing the Link 1000

Chapter 2 gives:

• An overview of the installation process

• A list of installation tools and equipment

• Installation procedures We recommend that you read the entire

chapter so you can plan the installation and obtain all the materials you need before starting the installation.

Planning the Installation

Supplied Parts

❐ Link 1000 control panel and 4 mounting screws ❐ 500 amp precision shunt ❐ 25 foot RJ11 phone cable ❐ Owner’s guide

Materials You Need to Supply

Refer to Figure 2 on page 12.

❐ Wire harness to connect the Link 1000 control panel to

the shunt and to the positive battery terminal. You can use 18AWG, twisted pair, for this wiring. You can also buy the harness from the dealer you bought the Link 1000 from or from West Marine.

Contact West Marine at:

• 1-800-BOATING (Canada and US)

• Fax: 1-831-761-4421 (Canada and US) When ordering the harness, quote these part numbers:

• 84-2014-00: 25 foot (7.62m) 8-conductor twisted pair

wire

• 84-2015-00: 50 foot (15. 24m) 8-co nductor twiste d pair

wire

❐ Appropriately sized copper cable and connectors to

connect the shunt to the battery and the negative bus for DC loads

Consult a local cable supplier about cable size and connector type. You may find it convenient to have the cable supplier attach the connectors.

❐ 2, 2 amp fuses and fuse holders. (Three fuses and fuse

holders if you are monitoring a second battery.)

❐ 2 screws to mount the shunt

Tools

Planning the Installation

❐ 2 strain reliefs (cable clamps) for the wires and phone

cable coming out the back of the control panel

❐ Anti-corrosive spray ❐ High current shunt. If your starter current exceeds 500

amps for more than ten seconds, you will need a heavy duty (1000 amp) shunt instead of the 500 amp shunt that is supplied with the Link 1000. (You can also use a separate engine starting battery whose negative is connected directly to the engine.) The heavy duty shunt part number is 84-2-13-00.

❐ Wire cutt er and stripper ❐ Small slot head screwdriver (for the screws on the

terminal block)

❐ Phillips screwdriver (for the control panel mounting

screws)

❐ Needle-nose pliers ❐ 9/16 in. wrench to secure cables to the shunt

Installation Considerations

Safety

• If you are using flooded lead-acid batteries, install them in a separate battery compartment.

• Wiring should be in accordance with NEC, ABYC, or other applicable national or regional codes.

Performance

• Do not connect anything other than the shunt to the negative battery terminal. Connect all other loads and sources to the load side of the shunt. (See Figure 2.)

Planning the Installation

• The shunt sense leads must be 18AWG twisted pair wires.

• Install fuses within seven inches (18cm) of the battery.

Color-Coded Wiring

To avoid confusion during installation, Xantrex recommends that you buy wires that have the same color coding as shown in Figure 2.

Twisted Pair Wires

If you wish, you can make you r own twist ed pairs by t wisting together two wires with a twist every inch. If you make your own twisted pair, wrap tape around the wire s ev ery twelve or sixteen inches (30 to 40cm) to keep the wires together and to make them easier to pull through holes and raceways.

Separate Engine Starting Battery

In order to monitor start batte ry volta ge, you need to connect a sense lead from the Link 1000 terminal blo ck to the positi ve battery terminal of the starting battery. This procedure also requires a 2 amp fuse and fuse holder. See step 6 on page 16 for installat io n de ta ils, and see page 33 for i nf ormat ion about turning this function on.

Installing the Link 1000

Overview of Installation Steps

Complete the installation in this order. Refer to Figure 2.

1. Mount the control panel (page 13).

2. Mount the shunt, and cable it to the negative battery terminal. Cable the load side of the shunt to the negative bus for DC loads (page 14).

3. Connect wires to the Link 1000 terminal block (page 15).

4. Connect wires from th e terminal block to the shunt and to the battery’s positive terminal (page 16).

5. Install the fuses (page 17).

6. Connect the phone cable to the control panel and the inverter/charger (page 17).

Installing the Link 1000

Rear of Link 1000

Control Panel

12345

678

Violet

Phone Cable

System Negative

500A

Shunt

Battery

Side

Orange

Negative

Gnd. Stud

Load Side

Green

Battery

Inverter/Charger

Engine Starter

Black

Cable Jacket

Blue

Distribution

Start

Battery

Red

Pos.

2 Amp Fuses

Neg.

Distribution

Figure 2 System Overview (Wiring)

Mounting the Link 1000 Control Panel

The Link 1000 control panel c onsist s of a displ ay panel and a mounting plate.

To mount the control panel:

1. Separate the display panel and the mounting plate.

Display Panel

Installing the Link 1000

Mounting Plate

Figure 3 Display Panel and Mounting Pl ate

2. If you are going to run the phone cord and wires through the opening in the rear of the mounting plate, make a cutout in the mounting surface using the mounting plate as a template. (You can also run the phone cord and wires down from the bottom of the mounting plate.)

3. Screw the mounting plate to the mounting surface as shown in Figure 4.

Installing the Link 1000

Countersunk

Screw

Pan Head

Screw

Figure 4 Link 1000 Mounting Plate

Cutout for Cables and Phone Cable

Mounting and Cabling the Shunt

To mount and cable the shunt:

1. Screw the shunt to a suitable mounting surface.

2. Connect the shunt to the negative terminal of the battery using ring terminals or locked spade terminals on a copper cable that is sized appropriately for the current carrying capacity of the system.

Pan Head

Screw

Countersunk

Screw

Ensure that no other wires are connected directly to the negative battery terminal or to the negative side of the shunt. All current must flow through the shunt.

3. Connect the loa d si de of the shunt to the negative bus for DC loads using a copper cable that is size d appr opriately for the current carrying capacity of the system.

If you are not using a ne gative bus for DC loads, connect the load side of the shunt to the negative side of the system.

Wiring the Terminal Block

Prepare for wiring by following these guidelines:

• Pull the wi res and th e phone c able thro ugh the openi ng in the mounting plate (unless you are running them down from the bottom of the mounting plate).

• Prepare the wires by giving each:

• A clean cut

•A clean strip

• A tightly twisted end

• Loosen the terminal block screws, pry the wire clamps open with a paper clip, and insert the wires using needlenose pliers.

• Tighten the screws firmly, but do not overtighten.

To wire the terminal block:

• Insert the wires in the terminal block following the sequence shown below.

Note: Terminal 1 is next to the phone cable jack.

Installing the Link 1000

Terminal

1Black. Control panel negative to the large bolt on the

2 Green. Sense lead to the load side of the shunt. 3Orange. Sense lead to the battery side of the shunt. 4Blue. Vo ltage se nse lead to the positive b attery

5Red. Power lead to the positive battery terminal. 6 Violet. Voltage sense lead to the positive battery

7 Not used 8 Not used

Wire Color and Function

load side of the shunt.

terminal.

terminal. Connect this lead if you are monitoring the voltage of a second (starting) battery.

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