Xantrex Technology TM500A User Manual

TM500A
Battery Status Monitor
Installation & Operator’s Guide
About Xantrex
Trademarks
Trace is a trademark of Xantrex Technology Inc. Xantrex is a registered trademark of Xantrex Technology Inc.
Notice of Copyright
Xantrex TM500A Battery Status Monitor © May 2001 Xantrex Technology. All rights reserved.
Disclaimers
While every precaution has been taken to ensure the accuracy of the contents of this guide, Xantrex Technology Inc., assumes no responsibility for errors or omissions. Note as well that specifications and product functional­ity may change without notice.
Since the use of this manual and the conditions or methods of installa­tion, operation, use and maintenance of the unit are beyond the control of Xantrex Technology Inc., the company does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of or any way connected with such installation, operation, use, or maintenance.
Due to continual improvement through product updates, photographs and/or illustrations used in this manual may not exactly match your unit. Xantrex Technology Inc., reserves the right to update this product without notice or releasing an updated manual when fit, form or function are not affected.
Date and Revision
May 2001, Revision A
Part Number
973-0012-01-02
Contact Information
Web: www.xantrex.com
Email: tracewarranty@traceengineering.com
Phone: 360/435.8826
Fax: 360/474.0616
© 2001 Xantrex Technology Inc.
P/N 973-0012-01-02 Rev. A 05/01
Table of Contents
1.0 INTRODUCTION ............................................................... 1
The TM500A .......................................................................................... 1
Unpacking and Inspection ..................................................................... 2
TM500A (12/24 Volt) ............................................................................. 2
TM500A - NS (12/24 Volt) ..................................................................... 2
TM48 (48 Volt) ....................................................................................... 2
2.0 INSTALLATION ................................................................3
Required Tools ....................................................................................... 3
Pre-Installation ....................................................................................... 3
Mounting ................................................................................................ 3
Surface Mounting .............................................................................. 4
Flush Mounting .................................................................................. 6
Extended Length Installations ........................................................... 8
Deltec™ Shunt ...................................................................................... 9
Mounting/Wiring the Shunt ................................................................ 9
Mounting Circuit Board to an Existing Shunt .................................. 10
Connecting the Shunt Board ........................................................... 11
3.0 CONFIGURATION ........................................................... 12
Setup ................................................................................................... 12
Restoring the Factory Defaults ........................................................... 12
Setting Parameters .............................................................................. 13
Charge Efficiency %.......................................................................... 14
Setting the Charge Efficiency Factor ............................................. 14
Amp Hours Ah.................................................................................... 15
Setting the Amp Hours .................................................................... 15
CHARGED Indicator Setup ............................................................ 17
Trigger on Voltage Only ..................................................................... 17
Trigger on Voltage and Amperage .................................................. 19
Trigger on Voltage and Time ........................................................... 21
Charger Considerations .................................................................. 23
Relay Chargers ........................................................................... 23
Taper Chargers ........................................................................... 23
Three-stage Chargers ................................................................ 23
Low-Voltage Indicator V................................................................... 24
Configuring the Low-Voltage Alarm ............................................... 24
© 2001 Xantrex Technology Inc. P/N 973-0012-01-02 Rev. A 05/01
i
Table of Contents
(continued)
4.0 OPERATION ................................................................... 25
Indicators and Controls ....................................................................... 25
Buttons ................................................................................................ 25
Select Button ................................................................................... 25
Reset Button .................................................................................... 25
INVERTER ON/OFF Button .............................................................. 25
Basic Meters ....................................................................................... 26
Available Meters ............................................................................. 26
% (state-of charge) .................................................................... 26
V (Volts) ...................................................................................... 26
A (AMPS) ..................................................................................... 26
Ah (AMP HOURS) ....................................................................... 27
Power Saving Mode ........................................................................ 27
Data Monitors ...................................................................................... 28
Reminders and Indicators ................................................................... 30
Amp-hour Reminder ........................................................................ 30
Low-Voltage Indicator..................................................................... 31
CHARGED Indicator ......................................................................... 32
5.0 TROUBLESHOOTING .................................................... 33
6.0 SERVICE INFORMATION ............................................... 34
7.0 SPECIFICATIONS .......................................................... 35
8.0 WARRANTY.................................................................... 36
ii
© 2001 Xantrex Technology Inc.
P/N 973-0012-01-02 Rev. A 05/01
IMPORTANT SAFETY INSTRUCTIONS
This manual contains important safety instructions that should be followed during the installation and maintenance of this product.
To reduce the risk of electrical shock, and to ensure the safe installation and operation of this product, the following safety symbols have been placed throughout this manual to indicate dangerous conditions and important safety instructions.
WARNING - A dangerous voltage or condition exists in this area. Use extreme caution when performing these tasks.
AVERTISSEMENT - Une tension ou condition dangereuse existe dans cette zone. Faire preuve d’extrême prudence lors de la réalisation de ces tâches.
CAUTION - This procedure is critical to the safe installation or operation of the unit. Follow these instructions closely.
ATTENTION - Cette procédure est essentielle à l’installation ou l’utilisation de l’unité en toute sécurité. Suivre ces instructions de près.
NOTE - This statement is important. Follow instructions closely.
NOTE - Cette déclaration est importante. Suivre les instructions de
près.
All electrical work must be done in accordance with local, national, and/or international electrical codes.
Before installing or using this device, read all instructions and cautionary markings located in (or on) the TM500A, the manual, the batteries, the inverter, the PV array, etc.
Do not expose this unit to rain, snow or liquids of any type. This product is designed only for indoor mounting.
To reduce the chance of short-circuits when installing or working with the inverter, the batteries, or the PV array, use insulated tools.
Remove all jewelry such as rings, bracelets, necklaces, etc., while installing this system. This will greatly reduce the chance of accidental exposure to live circuits.
The inverter contains more than one live circuit (batteries, PV array, and AC). Power may be present at more than one source.
This product contains no user-serviceable parts. Do not attempt to repair this unit.
© 2001 Xantrex Technology Inc. P/N 973-0012-01-02 Rev. A 05/01
iii
BATTERY SAFETY INFORMATION
Always wear eye protection, such as safety glasses, when working with batteries.
Remove all loose jewelry before working with batteries.
Never work alone. Have someone assist you with the installation or be close enough to come to your aid when working with batteries.
NEVER smoke in the vicinity of a battery or generator.
Always connect the batteries first, then connect the cables to the inverter via a DC disconnect switched OFF. This will greatly reduce the chance of spark in the vicinity of the batteries.
Use insulated tools when working with batteries.
When connecting batteries, always verify proper voltage and polarity.
Do not short-circuit battery cables. Fire or explosion can occur.
In the event of exposure to battery electrolyte, wash the area with soap and water. If acid enters the eyes, flood them with running cold water for at least 15 minutes and get immediate medical attention.
iv
SAVE THESE INSTRUCTIONS
© 2001 Xantrex Technology Inc.
P/N 973-0012-01-02 Rev. A 05/01

1.0 INTRODUCTION

The TM500A

The TM500A features six data monitoring functions and three indicators
including:
• State of charge/amp-hour content (full or percent of capacity)
• State of charge/voltage (real-time voltage level, historical high and low system voltage)
• Amps (real-time amps, total charging amps, total load amps)
• Amp hours removed
• Days since fully charged
• Cumulative amp hours
• Recharge indicator
• Low-voltage indicator
• Full-charge indicator
The unit is configurable for specific system or application functions such as setting the CHARGED indication parameters, battery capacity, charging efficiency, low-battery warning conditions and a recharge reminder. The TM500A can monitor any battery supply from approximately 8 to 65 volts, track energy consumption and estimate remaining battery life.
In addition to its status monitoring features, the unit can act as a remote control, switching the inverter OFF or ON (only on inverters incorporating an RC4/RC8 compatible remote control jack).
The TM500A operates on 12-, 24-, or 48-volt battery systems (48-volt systems require an optional shunt board).
© 2001 Xantrex Technology Inc. P/N 973-0012-01-02 Rev. A 05/01
14.2
Figure 1-1
The TM500A
1
1.0 INTRODUCTION

Unpacking and Inspection

Upon receiving the TM500A, check that the following items are included.

TM500A (12/24 Volt)

• TM500A (meter panel, adaptor and mounting bracket)
• Manual
• 50-foot communications cable
• Deltec™ 500 amp/50 mV shunt
• 12/24 volt shunt-printed circuit board with in-line 2-amp fuse

TM500A - NS (12/24 Volt)

• TM500A (meter panel, adaptor and mounting bracket)
• Manual
• 50-foot communications cable
• Shunt-printed circuit board with in-line 2-amp fuse

TM48 (48 Volt)

• 48-volt shunt-printed circuit board with in-line 2-amp fuse
2
© 2001 Xantrex Technology Inc.
P/N 973-0012-01-02 Rev. A 05/01

2.0 INSTALLATION

Required Tools

• Phillips screw driver
• 3/32" and 3/16" drill bits
• Hole saw
If the TM500A will also function as a remote control (INVERTER ON/OFF), an additional cable must be ordered. Available lengths are:
10 feet–TC/10 25 feet–TC/25 50 feet–TC/50 100 feet–TC/100

Pre-Installation

Before installing the TM500A, read all instructions and cautionary markings located in this manual. The unit should be mounted in a clean, dry, protected environment.
Determine the wire route to the batteries (and inverter, if the remote INVERTER ON/OFF function is desired).
NOTE: Check for existing electrical, plumbing or other potential areas of accidental damage prior to making cuts in structural surfaces.

Mounting

The unit can be surface mounted (using the adaptor supplied) or flush mounted into a rectangular opening. Provide at least one inch clearance behind the meter circuit board for the cabling when flush mounting.
The TM500A ships in three sections:
• TM500A
• Adaptor for surface mounting
• Mounting Bracket
© 2001 Xantrex Technology Inc. P/N 973-0012-01-02 Rev. A 05/01
Trace Meter
Panel
TM500A and Mounting Components
Adaptor
Figure 2-1
Mounting
3
2.0 INSTALLATION

Surface Mounting

• Using the mounting bracket as a template, mark the positions for the screw holes and an area where the cable(s) will feed through.
• Drill out the four screws holes (if required) and wire access opening. Use a 3/16" bit if the supplied plastic anchors are used. If placing the screws directly into the backing material, use a 3/32" bit. The wire access hole should be at least 1/2" diameter to allow the connector to pass through.
• Mount the bracket using the screws (and anchors if necessary) supplied. See Figure 2-2. Do not overtighten the screws.
• Install the adaptor onto the bracket by pressing it tightly into place.
• Connect the communications cable (from the shunt) to the “J1 TO SHUNT ONLY” jack on the TM500A. See Figure 2-3.
• If the TM500A is to function as an ON/OFF remote control for the inverter, connect the remote control cable (not supplied) to the “J2 INVERTER ONLY” jack. This connector only functions if the inverter contains a REMOTE jack that allows operation with an RC4 or RC8 remote control.
CAUTION: Do not reverse these cables or the TM500A circuit board will be permanently damaged.
• Install the meter onto the adaptor by pressing it tightly into place.
4
© 2001 Xantrex Technology Inc.
P/N 973-0012-01-02 Rev. A 05/01
Wire
Access
Hole
Trace Meter
Bracket
Trace Meter
Adaptor
2.0 INSTALLATION
Trace Meter
Surface Mounting the TM500A Using the Adaptor
Figure 2-2
J2 TO
INVERTER
ONLY
SPADE LUG
J1 TO
SHUNT
ONLY
Figure 2-3
Communication and Remote Cable Connections
© 2001 Xantrex Technology Inc. P/N 973-0012-01-02 Rev. A 05/01
5
2.0 INSTALLATION

Flush Mounting

To flush mount the TM500A , an opening must be cut in the backing material to allow room for the circuit board, wires and connectors. Allow at least one inch depth behind the circuit board for the connectors and wires.
• Use the bracket as a template and mark the positions for the screw holes. Mark the open area to be cut out for the circuit board.
NOTE: Carefully cut out the circuit board area from the backing material (i.e., wallboard). Cut inside the lines so there is enough area left to securely hold the screws.
• Drill out the four screw’s holes (if required) and wire access opening. Use a 3/16" bit if the supplied plastic anchors are used. If placing the screws directly into the backing material, use a 3/32" bit.
• Mount the bracket using the screws (and anchors if necessary) supplied. See Figure 2-4. Do not overtighten the screws.
• Connect the communications cable (from the shunt) to the “J1 TO SHUNT ONLY” jack (Figure 2-5).
• If the TM500A is to function as an ON/OFF remote control for the inverter, connect the remote control cable (not supplied) to the “J2 INVERTER ONLY” jack. This connector only functions if the inverter contains a REMOTE jack that allows operation with an RC4 or RC8 remote control.
CAUTION: Do not reverse these cables or the TM500A circuit board will be permanently damaged. This is not covered under warranty.
• Install the meter onto the bracket by pressing it tightly into place.
6
© 2001 Xantrex Technology Inc.
P/N 973-0012-01-02 Rev. A 05/01
Area To Be Cut-Out
Trace Meter
Bracket
2.0 INSTALLATION
Trace Meter
Flush Mounting the TM500A
Figure 2-4
J2 TO
INVERTER
ONLY
SPADE LUG
J1 TO
SHUNT
ONLY
Figure 2-5
Communication and Remote Cable Connections
© 2001 Xantrex Technology Inc. P/N 973-0012-01-02 Rev. A 05/01
7
2.0 INSTALLATION

Extended Length Installations

If the TM500A is mounted in excess of 100 feet from the inverter, an additional wire (with a spade lugs on both ends) must be connected between the TM500A and shunt spade lugs. This wire acts as a ground reference and ensures the meter will read accurately.
Use the following gauge wire for the distance the TM500A is mounted from the inverter.
Maximum Distance Wire Gauge
250 feet #16 AWG 400 feet #14 AWG 630 feet #12 AWG
1000 feet #10 AWG
J2 TO
INVERTER
ONLY
J1 TO
SHUNT
ONLY
SPADE LUG
Interconnect for distances over
100 feet
SPADE LUG
Figure 2-6
Extended Length Ground Wire
8
© 2001 Xantrex Technology Inc.
P/N 973-0012-01-02 Rev. A 05/01
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